Brick/block laying machine incorporated in a vehicle

ABSTRACT

A self-contained truck-mounted brick laying machine (2) is described. A truck (1) supports the brick laying machine (2) which is mounted on a frame (3) on the truck chassis. The frame (3) supports packs or pallets of bricks (52, 53) placed on a platform (51). A transfer robot can then pick up an individual brick and move it to, or between either a saw (46) or a router (47) or a carousel (48). The carousel is located coaxially with a tower (10), at the base of the tower (10). The carousel (48) transfers the brick via the tower (10) to an articulated (folding about horizontal axis (16)) telescoping boom comprising first boom element in the form of telescopic boom (12, 14) and second boom element in the form of telescopic stick (15, 17, 18, 19, 20). The bricks are moved along the folding telescoping boom by linearly moving shuttles, to reach a brick laying and adhesive applying head (32). The brick laying and adhesive applying head (32) mounts to element (20) of the stick, about an axis (33) which is disposed horizontally. The poise of the brick laying and adhesive applying head (32) about the axis (33) is adjusted and is set in use so that the base (811) of a clevis (813) of the robotic arm (36) mounts about a horizontal axis, and the tracker component (130) is disposed uppermost on the brick laying and adhesive applying head (32). The brick laying and adhesive applying head (32) applies adhesive to the brick and has a robot that lays the brick. Vision and laser scanning and tracking systems are provided to allow the measurement of as-built slabs, bricks, the monitoring and adjustment of the process and the monitoring of safety zones. The first, or any course of bricks can have the bricks pre machined by the router module (47) so that the top of the course is level once laid.

TECHNICAL FIELD

This invention belongs to the field of building construction, andrelates to a pick and place machine to build a building from bricks orblocks.

BACKGROUND ART

The following discussion of the background art is intended to facilitatean understanding of the present invention only. It should be appreciatedthat the discussion is not an acknowledgement or admission that any ofthe material referred to was part of the common general knowledge as atthe priority date of the application.

The inventor previously described a brick laying machine in U.S. Pat.No. 8,166,727. In practice, as described, this required a largeroad-going machine to implement.

An early prototype brick laying machine, based on that described in U.S.Pat. No. 8,166,727, and built by the inventor, used a chain conveyorwith brick holding clamps attached to the chain. This chain moved fromthe base of the machine, out along a boom, to the laying head system.There was a small chain take up mechanism to take up variations in chainlength due to changes in boom geometry. The take up mechanism alsoallowed some independence between the brick preparation and the laying,however the relatively short length of the take up mechanism meant thatthe brick preparation and the laying head needed to be synchronised atleast some of the time. This meant that the slowest process limited theprogress of bricks through the chain. Depending on the process of thecurrent bricks being laid, either the brick preparation or the layinghead could be the slowest process.

The chain followed a relatively complex path around the boom andtelescopic stick so that as the telescopic stick was extended, the totalchain length remained the same. The chain had brick griping clampsattached to it, so as it wrapped back and forth, it took up considerablespace. If the telescopic stick had many stages, the amount of spacetaken up by the chain and grippers would greatly increase, making theboom and stick assembly larger than is desirable for road transport.

A brick conveyor using flat belts was investigated by the inventor. Thisrequired a substantially level orientation of the boom and telescopicstick and would require other means of moving the bricks vertically toaccommodate for the change in laying height as the structure is builtcourse by course. It was also determined that some cut bricks could bequite short compared to their height and would be unstable iftransported on a flat belt conveyor. In the case of a telescopic stickand boom, dealing with excess belt length would encounter the sameproblems as the chain conveyor.

It is therefore an object of this invention to provide a brick layingmachine that could be incorporated into a road-going vehicle, and wouldovercome at least some of the aforementioned problems, while maintainingthe utility of the inventor's previously described machines.

Throughout the specification unless the context requires otherwise, theword “comprise” or variations such as “comprises” or “comprising”, willbe understood to imply the inclusion of a stated integer or group ofintegers but not the exclusion of any other integer or group ofintegers.

In this specification the word “brick” is intended to encompass anybuilding element such as a brick or block, to be placed during theconstruction of a building or wall or the like.

SUMMARY OF INVENTION

In accordance with the invention, there is provided a brick layingmachine incorporated in a vehicle, said machine having a foldable boom,foldable about at least one folding axis, said foldable boom beinglocatable in a folded stowed position longitudinally along said vehicle,and moveable to unfolded extended positions away from said vehicle; saidboom having a near end arranged for pivotal movement about a firsthorizontal axis located on a turret, said turret being rotatable about avertical axis; said foldable boom having first conveying apparatus toconvey bricks therealong, to a brick laying and adhesive applying headlocated at a remote end of the foldable boom, and having fluid conveyingapparatus to convey adhesive therealong, to an adhesive applicatorlocated in said brick laying and adhesive applying head said machinehaving a carousel extending at least partially around said turret nearthe base thereof, said turret having second conveying apparatus toconvey bricks vertically from said carousel to said first conveyingapparatus, said carousel being rotatable about a vertical axis topresent a brick for access by said second conveying apparatus; saidmachine having at least one brick machining tool located beside saidstowed position and having a loading bay to receive packs of bricks;said machine having programmable brick handling apparatus to conveybricks one by one from said loading bay to said carousel, optionally viasaid at least one brick machining tool, as pre-programmed.

Preferably said first conveying apparatus comprises at least one shuttleequipped with a clamp to releasably hold a brick, said shuttle runningalong a track extending along said boom.

Preferably said foldable boom comprises a first boom element and asecond boom element pivotable about a said folding axis spaced from saidfirst horizontal axis, and parallel therewith.

Preferably each boom element has a said track and at least one saidshuttle.

Preferably at least one of said first boom element and said second boomelement, has further elements arranged in telescoping interconnection.

Preferably both said first boom element and said second boom elementhave further elements arranged in telescoping interconnection.

Preferably said elements are tubular, preferably rectangular or squarein cross-section.

Preferably each element has a said track and one said shuttle arrangedto run along said track, between opposed ends of each said element.

Preferably said tracks are arranged located internally inside saidelements, and said shuttles run inside their respective elements.

Preferably said track runs along one side of a said boom element, andruns along an opposite side of an immediately interconnecting said boomelement, so that the shuttle located in the tracks of both boom elementscan locate opposite each other in order to effect transfer of a brickfrom the clamp of one shuttle to the clamp of the other shuttle.

Preferably a said track runs along one side of a said boom element, andruns along the same side of an adjacent said boom element connectedabout a said folding axis, and a pivoting shuttle equipped with a clampto hold a brick is provided, pivoting about said folding axis, totransfer a brick between shuttles in boom elements connected about saidfolding axis.

Preferably said tracks in the aforementioned arrangement run along thelengths of the boom elements on the side opposite to the side where thefolding axis is located.

Preferably the distal telescoping element of said first boom element issmaller in cross sectional dimensions than the interconnected element ofsaid second boom element connected about said folding axis, and saiddistal telescoping element is offset relative to said folding axis, tosubstantially centrally align the pathway through said elements at thefolding axis, when the elements are interconnected about said foldingaxis substantially in a straight line.

Preferably, in the shuttle in the interconnected element of said secondboom element connected about said folding axis, the clamp there ofincludes a deviation in its arms to provide clearance for the intrudingpart of the distal telescoping element of said first boom element, whenthe elements are interconnected about said folding axis substantially ina straight line.

Alternatively, the distal telescoping element of said first boom elementis different in cross sectional dimensions from the interconnectedelement of said second boom element connected about said folding axis,and the smaller of the elements is offset relative to said folding axis,to substantially centrally align the pathway through said elements atthe folding axis, when the elements are interconnected about saidfolding axis substantially in a straight line. Preferably, in theshuttles in the boom elements connected about said folding axis, theclamp of the shuttle contained in the boom element having a greatercross-sectional size includes a deviation in its arms to provideclearance for the intruding part of the boom element with the lessercross-sectional size, when the boom elements are interconnected aboutsaid folding axis substantially in a straight line.

Preferably said track runs along one side of one element, and runs alongan opposite side of an immediate interconnecting telescoping element, sothat the shuttles located in the tracks of both elements can locateopposite each other in order to effect transfer of a brick from theclamp of one shuttle to the clamp of the other shuttle.

Preferably the internal interconnecting telescoping elements have a voidat their near ends opposite said track therein to allow their shuttlesto access shuttles of outer tubular elements to enable the clampsthereof to transfer a brick there-between.

It will be understood that where there are three or more telescopingelements, the track of the first third and fifth elements will belocated on one side of these elements, while the tracks of the secondand fourth elements will be located on the opposite side. The shuttleswill run along the length of the elements, at least as far as they havebeen telescopingly extended, passing a brick from one said element tothe next, and so on, to effect transfer of the brick along the extent ofthe telescoping part of the folding boom.

At the folding axis of the two boom elements, the folding axis extendshorizontally on the underside of the boom elements, and a pivotingshuttle pivots about the same folding axis. The tracks run along the topof the boom elements that are connected about the folding axis, with theclamps of the shuttles extending down away from the tracks. The clamp onthe pivoting shuttle extends upward away from the folding axis. Thetracks of the boom elements that are connected about the folding axisoverlap in the same manner, so that a shuttle arrives at the foldingjunction with a brick, the pivoting shuttle clamps the brick before theshuttle moves away, the pivoting shuttle pivots as necessary to alignwith the next boom element and presents the brick to the shuttle in thenext boom element, to effect transfer of the brick between the shuttlesof the elements at the folding intersection.

Preferably the second conveying apparatus comprises a turret trackextending vertically along said turret, said turret track having ashuttle with a turret shuttle clamp to clamp a brick, the shuttleconveying the brick from the carousel to the shuttle in the near end ofthe foldable boom.

Preferably the turret supports a brick rotating mechanism having a clampto clamp a brick presented by said turret shuttle clamp, said brickrotating mechanism being provided to rotate a brick so that itslongitudinal extent aligns with the longitudinal extent of said firstboom element, for presentation to a said at least one shuttle.

Preferably the brick rotating mechanism has a clamp to clamp a brick,and is mounted about said first horizontal axis.

Preferably the carousel has a carousel clamp to clamp a brick receivedfrom the programmable brick handling apparatus. In use, the carousel isrotated to align its clamp with the clamp of the shuttle on the turrettrack, so the brick can be transferred from the carousel clamp to theturret shuttle clamp, before the turret shuttle transfers the brickalong the turret track to reach the first shuttle of the foldable boom.Preferably the carousel clamp can pivot from a first position in whichit receives a brick from the programmable brick handling apparatus to asecond position in which it presents the brick to the turret shuttleclamp.

Preferably said turret, said carousel and said stowed position arelocated along a central longitudinal axis of said vehicle.

Preferably said at least one brick machining tool comprises a firstbrick machining tool including a saw located to one side of the stowedposition, and a second brick machining tool including a router locatedto the other side of the stowed position.

Preferably said first brick machining tool includes a clamp located toclamp a brick on a side of a saw cutting blade position.

Preferably said first brick machining tool includes a clamp configuredto clamp a brick on each side of a saw cutting blade position. In thismanner the brick and the waste portion thereof are secured to preventdamage during the cutting action, and the cut brick and saw blade can beseparated before the clamp releases the cut brick portions.

Preferably said first brick machining tool is contained in an enclosurewith a cover providing access for placement and removal of a brick bysaid programmable brick handling apparatus.

Preferably said second brick machining tool is contained in an enclosurewith a cover providing access for placement and removal of a brick bysaid programmable brick handling apparatus.

Preferably the second brick machining tool includes a clamp to clamp abrick, and an orientation assembly to orient the clamped brick in spaceto present to the router, to route slots and notches in bricks in orderto chase cabling, or to mill bricks to a predetermined required height.

Preferably the router in the second brick machining tool is mounted on atri-axis motion assembly for moving the router in any combination ofmovement in three dimensions. This is preferably in the x and y axesacross the brick, and in the z axis into the brick.

Preferably the second brick machining tool includes a tool storagemagazine spaced away from the clamp and orientation assembly andaccessible by said router at a predetermined position of said tri-axismotion assembly, to access or store a routing bit or milling bit. Thetool storage magazine may store a number of different bits to allowdifferent cuts to be made by the router.

Preferably said brick laying and adhesive applying head is pivotallymounted for controlled rotation to the remote end of the foldable boomabout a second horizontal axis located on a clevis, said brick layingand adhesive applying head having associated therewith a pivotable clampto receive and clamp a brick presented by said first conveyingapparatus, said pivotable clamp being pivotally mounted about saidsecond horizontal axis; said brick laying and adhesive applying headsupporting said adhesive applicator to apply adhesive to a brickpresented by said pivotable clamp; said brick laying and adhesiveapplying head having a brick laying head mounted thereto by a mountlocated in a position away from said clevis, said brick laying headhaving a brick laying clamp moveable between a position to receive andclamp a brick held by said pivotable clamp, to a position in which saidbrick is released and laid.

Preferably said brick laying and adhesive applying head is pivotallymounted for controlled rotation to the remote end of the foldable boomabout a second horizontal axis located on a clevis, said brick layingand adhesive applying head having associated therewith a pivotable clampto receive and clamp a brick presented by said first conveyingapparatus, said pivotable clamp being pivotally mounted about saidsecond horizontal axis; said brick laying and adhesive applying headsupporting said adhesive applicator on a distal end of a tongue member,said tongue member being housed in a sheath for linear movement toextend said adhesive applicator across a brick presented by saidpivotable clamp, and retract said tongue within said sheath to withdrawsaid adhesive applicator away from said pivotable clamp; said bricklaying and adhesive applying head having a brick laying head mountedthereto by a mount located in a position away from said clevis, saidbrick laying head having a brick laying clamp moveable between aposition to receive and clamp a brick held by said pivotable clamp, to aposition in which said brick is released and laid; said sheath extendingaway from said second horizontal axis, and substantially along saidclevis toward said mount, to provide clearance between said sheath andsaid brick laying head in order to allow operation without interference.

Preferably, said tongue is rigid when extended obliquely or horizontallyand freely deflectable in only one dimension upwardly about horizontalaxes away from said second horizontal axis only (i.e. freely deflectableupwardly but not from side to side, much in the same way as a humanfinger is moveable, palm facing up). This restriction in movement allowscontrolled application of adhesive to a surface, which typically will bedisposed horiziontally. Particularly it allows the adhesive applicatorhead to be moved linearly relative to the surface, in a controlledmanner.

Preferably said sheath has a tip which is, in use located horizontally,so that said tongue extends horizontally from the tip of said sheath.

Preferably said sheath curves upwardly to extend between said mount andsaid second horizontal axis, and the tongue being freely deflectableabout horizontal axes allows the tongue to move within said sheath.

Preferably said tongue is configured as a chain-link-type actuator, saidchain-link-type actuator being linearly moveable by a driven sprocket toselectively extend and retract said tongue from said tip of said sheath.

Preferably said chain link type actuator comprises a chain having bodyportions attached to one side, said body portions having ends thatcontact ends of adjacent body portions preventing said chain foldingabout said horizontal axes in one direction away from a horizontalalignment of said chain.

Preferably said tongue comprises a plurality of body portions, each bodyportion having on a top surface at least one pivot mount with atransverse aperture extending horizontally there-through to provide aconnection point for a chain link to an adjacent said pivot mount of anadjacent said body portion, each said body portion having opposed endsthat contact ends of adjacent body portions, said tongue being foldablein one direction only about said transverse apertures, the opposed endsof adjacent body portions coming into contact preventing said tonguefolding about said connection points in the opposite direction.

Preferably each said body portion has a channel extending longitudinallythere-through, for routing services such as wiring and tubing for thetransport of adhesive to said adhesive applicator. The channel may be aninverted u-channel with the pivot mounts being located on top of theweb.

Preferably the channel is closed, to fully enclose said servicesextending longitudinally through said tongue.

Preferably there are two said pivot mounts located on top of each saidbody portion, one said pivot mount located near each opposed end of saidbody portion.

Preferably on each body portion, said pivot mounts are spaced apart fromeach other by the same longitudinal distance as the sum of thelongitudinal distances from each to the closest end of said bodyportion. In this manner, the pivot mounts can form teeth of a cog on topof the assembled tongue, to be engaged by a driven sprocket toselectively extend and retract said tongue from said tip of said sheath.

Preferably the angle of the faces forming the ends of each said bodyportion relative to the longitudinal extent of the body portion add upto 180 degrees. Most preferably the face forming each end of each saidbody portion is at right angles relative to the longitudinal extent ofthe body portion. With either arrangement, the tongue can extend outwardand be self supporting, and bendable upward only, about the chain linksthat interconnect them.

Preferably the pivotable clamp is mounted for rotation on the distal endof said second boom element.

Preferably said pivotable clamp is mounted on a linear sliding mountthat has travel extending in a direction linearly through said secondhorizontal axis and normal thereto.

Preferably the brick laying head includes a robotic arm assembly withsaid brick laying clamp to grip and lay a brick.

Preferably the brick laying head includes a spherical geometry robotwith said brick laying clamp to grip and lay a brick.

Preferably said brick laying head includes a linearly extendable armdepending downward, attached about a mount roll-axis to said mount, saidmount roll-axis allowing controlled roll motion in said arm relative tosaid mount, said brick laying clamp being mounted for controlled motionto the end of said linearly extendible arm about a universal jointallowing controlled pitch motion and controlled roll motion in saidbrick laying clamp relative to said arm, and said brick laying clamp ismounted to said universal joint on a rotatable mount for controlledrotation about a yaw axis.

The mount roll-axis will normally be longitudinal relative to the extentof the boom that the brick laying and adhesive applying head is attachedto, and disposed horizontally in normal operation, as controlled by aram or the like that controls the pose of the brick laying and adhesiveapplying head relative to the remote end of the foldable boom.

Preferably said mount includes a mount pitch-axis allowing controlledpitch motion of said arm relative to said mount. The mount pitch-axisruns transverse to the longitudinal extent of the linearly extendablearm.

Preferably said universal joint has a first wrist-axis pivotabletransverse to the longitudinal extent of said arm and a secondwrist-axis disposed normal to said first wrist-axis, both wrist-axesbeing normal to said yaw axis.

Preferably said linearly extending arm includes a linear guide whichconnects with said mount for controlled linear movement to extend andretract said arm in order to move said brick laying clamp toward or awayfrom said mount.

Preferably the brick laying clamp includes jaws that are independentlymoveable to clamp and unclamp a brick, and also selectively moveable inunison to offset the position of the jaws relative to the brick layingclamp. This allows the brick laying clamp to access a position to lay abrick, that may be up against an existing wall lying alongside one ofthe jaws of the brick laying clamp.

Preferably said brick laying machine includes a tracker componentmounted to said brick laying and adhesive applying head, wherein saidbrick laying and adhesive applying head has said robotic arm assemblywith said brick laying clamp to grip and lay a brick, and said bricklaying machine uses a tracker system to measure the position of thetracker component and applies compensating movement to the robotic armassembly to correct for variance between programmed tracker componentposition and measured tracker component position.

Preferably said brick laying machine includes a further trackercomponent supported on said brick laying clamp, and said brick layingmachine uses a further tracker system to measure the position of thefurther tracker component and applies further compensating movement tothe robotic arm assembly to correct for variance between programmedfurther tracker component position and measured further trackercomponent position

In accordance with another aspect of the invention, there is provided amachining tool for use in machining an item in an automated assemblyline, said machining tool having a chassis on which a machine tool issupported, a clamp with at least one set of jaws to support an item tobe machined, said at least one set of jaws being arranged for movementto adjust the position at which machining of said item takes place, anenclosure with at least one cover moveable between a closed position inwhich said enclosure is sealed to minimise egress of machining waste andnoise and an open position in which said clamp may be accessed by atransfer arm with grippers to insert said item before a machiningoperation and to remove said item after said machining operation, and adust extractor for debris removal from said enclosure, said dustextractor having an intake located in proximity to said machine tool anda suction hose to cause airflow entraining debris for removal.

Preferably said machine tool comprises a saw with a cutting blade, andsaid clamp is mounted on a table for sliding movement from said openposition in which said clamp may be accessed by said transfer arm,through said cutting blade to cut said item.

Preferably said clamp is configured with two sets of jaws to clamp saiditem on each side of a saw cutting blade position. In this manner theitem and the waste portion thereof are secured to prevent damage duringthe cutting action, and the cut item and saw blade can be separatedbefore the clamp releases the cut brick portions.

Preferably said machine tool comprises a router mounted for slidingmovement along three orthogonal axes, said clamp being located to clampsaid item in proximity to said cover, and arranged to rotate said itemabout an axis normal to a spindle axis of said router.

Preferably said clamp is mounted to an orientation assembly to orientthe clamped brick in space to present to the router, to route slots andnotches in bricks in order to chase cabling, or to mill bricks to apredetermined required height.

Preferably said router is mounted on a tri-axis motion assembly formoving the router in any combination of movement in three dimensions,with one of the three axes being said spindle axis, and the other twoaxes being normal to each other and the spindle axis. These axes arepreferably in the x and y axes across the brick, and in the z axis intothe brick.

Preferably the machine tool includes a tool storage magazine spaced awayfrom the clamp and orientation assembly and accessible by said router ata predetermined position.

Preferably said tool storage magazine is accessible by said router at apredetermined position of said tri-axis motion assembly, to access orstore a routing bit or milling bit. The tool storage magazine may storea number of different bits to allow different cuts to be made by therouter.

Preferably said tool storage magazine comprises a rotary magazinemounted about a horizontal axis and spaced to one side of said clamp.

The invention provides a truck mounted automated brick laying machine.In its most preferred form, the machine is configured so that the boomcan be folded so that the truck is within standard road transportdimension limits for rigid body trucks, and so is able to drive onpublic roads without requiring any special arrangements such as widevehicle escorts, special permits or the like.

In its most preferred form, the elements of the folded boom aretelescoping, with the first boom element mounted to the truck havingsufficient extension to reach the necessary elevation for the expectedheight of the building to be constructed, and the first boom element andsecond boom element preferably having sufficient combined extension toreach over the entire construction site.

When at the building site, the automated brick laying machine extendsstabilising legs and unfolds the boom. A tracking system is then set upto measure the position and orientation of the laying robot on the endof the boom.

Optionally a laser scanning device fitted to the end of the boom can bemoved over the slab in all areas where bricks will be laid. The scanningdevice scans the height and level of the slab to obtain a 3D profile.The control system compares the profile of the slab to the idealdesigned shape of the slab, fits the designed slab position to thelowest measured level of the actual slab (discounting any small lowareas that could be bridged by a brick) and calculates an amount andshape of material, if any, to be machined off each brick in the firstcourse so that after being laid, the top of the bricks in the firstcourse are level and at the correct height.

The boom tip is moved to automatically or semi automatically scan aconcrete slab. The location of the automatic brick laying machine andthe concrete slab is used to set working coordinate systems for theconstruction of a structure. The scan of the slab is also used tocalculate machining of the bricks laid in the first course of thestructure to correct for variations in the height, level and flatness ofthe slab.

Packs of bricks are loaded at the rear of the truck. Robotic equipmentde-hacks (unpack) the bricks and moves them optionally to or from anautomated saw, an automated 5 axis CNC router with automatictool-changer or to a carousel that then transports the bricks to aslewing, articulated and telescopic foldable boom. The bricks are passedfrom one shuttle to another along the boom to an automated adhesiveapplication robot that applies adhesive to the bricks.

A robotic flipper then inverts the brick and then a spherical geometryrobot grasps the brick and lays it on a structure being built. Thestructure is built course by course. The automated brick laying machineuses a tracking system to measure the position of the tip of the boomand applies compensating movement to the spherical geometry robot sothat the brick is laid in the correct 3D position.

The boom is provided with lifting hooks to assist with the manualplacement of items such as lintels, door frames and window frames.Optionally the spherical geometry robot can automatically place itemsother than bricks such as lintels, door frames and window frames.

The router is used to rout grooves in bricks so that when the bricks areplaced in the structure the grooves line up ready for the followinginsertion of pipes and or cables. The router may be used to sculptbricks. The router may be used to machine the top or bottom of bricks toallow for height correction of a course or in particular to machine thefirst course bricks to correct for the variation of height, flatness andlevel in a slab or the footings.

The automated saw is used to cut bricks to length or to cut bevels. Thisallows the bricks to be laid in standard or intricate patterns.

A software control system is used to control the automated brick layingmachine. The software control system is cognisant of which brick isbeing placed in which location, and the bricks are machined or cutaccording to their predetermined locations. Bricks can be machined inorder to provide chasing for plumbing, electrical wiring and otherservices. Such a control system may be as described in the internationalpatent application filed by the applicant titled “Computer Aided Designfor Brick and Block Constructions and Control Software to Control aMachine to Construct a Building”, with priority claim from Australianpatent application 2016902787, the contents of both of which areincorporated herein by cross reference.

The automated brick laying machine has computerised vision systemsand/or physical measuring probes to measure the bricks and check forquality, size and geometric shape, thereby allowing the machine toautomatically reject damaged or sub-standard bricks and automaticallyapply corrections to accurately lay bricks of sightly varying toleranceof shape or dimension.

BRIEF DESCRIPTION OF DRAWINGS

A preferred embodiment of the invention will now be explained in thefollowing description made with reference to the drawings, in which:

FIG. 1 shows a view of the automated brick laying machine 2 with itstruck base 1 with the boom and stick assembly 141 unfolded.

FIG. 2 shows a view of the automated brick laying machine 2 with theboom and stick assembly 141 folded and stowed for driving on a publicroad.

FIG. 3 shows a site plan of the automated brick laying machine 2 set upnear a concrete slab 136 on which the automated brick laying machine 2will build a structure not shown.

FIG. 4 shows a view of the truck 1 and the main frame 3 of the automatedbrick laying machine 2.

FIG. 5 shows a plan view of the automated brick laying machine 2.

FIG. 6 shows details of the enclosure 7 of the automated brick layingmachine 2.

FIG. 7 shows the first de-hacker bay 49.

FIG. 8 shows the enclosure frame 63 and items attached to it.

FIG. 9 shows a side view of the saw 46.

FIG. 10 shows a side view of the router 47.

FIG. 11 shows a cross section through the first stick 15 and secondstick 17.

FIG. 12 shows a side view of the brick laying and adhesive applying head32.

FIG. 13 shows a plan view and schematic diagram of the glue applicationsystem 150.

FIG. 14 shows a side view of a slab 136 with a first course 163 of aplurality of bricks 159, 160, 161, 162, 163.

FIG. 15 shows a view of the carousel 48.

FIG. 16 shows a view of the transfer robot 64.

FIG. 17 shows a view of the tower 10.

FIG. 18 shows a side view cross section of first boom 12.

FIG. 19 shows an end view cross section of first boom 12.

FIG. 20 shows a view of first boom 12.

FIG. 21 shows a view of shuttle-B1 224.

FIG. 22 shows a side view of shuttle-B1 224.

FIG. 23 shows a view of the tip end of boom 12 and a drive assembly 254.

FIG. 24 shows a view of the tower-first boom (T-B1) rotator 271 and thetower 10 and first boom 12.

FIG. 25 shows a view of the tower-first boom (T-B1) rotator 271.

FIG. 26 shows a view of the saw 46 fitted with an enclosure 100.

FIG. 27 shows a view of the saw 46 with the enclosure 100 not shown forclarity.

FIG. 28 shows a view of the saw clamping mechanism 94.

FIG. 29 shows a view of the saw clamping mechanism 94.

FIG. 30 shows a view of the router module 47.

FIG. 31 shows a view of the router module 47 with its enclosure 364removed for clarity.

FIG. 32 shows a view of the router module 47 with its enclosure 364removed for clarity.

FIG. 33 shows a view of the router module enclosure 364.

FIG. 34 shows a view of trunnion 414. The trunnion 414 is part of therouter module 47.

FIG. 35 shows a cross section of trunnion 414.

FIG. 36 shows the router moving column 463.

FIG. 37 shows a view of the router carriage 480 and ram 487.

FIG. 38 shows a view of the router carriage 480 and ram 487.

FIG. 39 shows a view of the second boom 14.

FIG. 40 shows a view of the second end 526 of second boom 14.

FIG. 41 shows a view of the second end 526 of second boom 14.

FIG. 42 shows a cross section side view of the second end 526 of secondboom 14.

FIG. 43 shows a view of the first end 525 of second boom 14.

FIG. 44 shows a view of the rotator-B2-S1 548.

FIG. 45 shows a view of the first stick 15.

FIG. 46 shows a view of the first end 561 of the first stick 15.

FIG. 47 shows a view of the second stick 17.

FIG. 48 shows a view of the first end 598 of the second stick 17.

FIG. 49 shows a view of the second end 599 of the second stick 17.

FIG. 50 shows a view of the third stick 18.

FIG. 51 shows a view of the first end 618 of the third stick 18.

FIG. 52 shows a view of the second end 619 of the third stick 18.

FIG. 53 shows a view of the fourth stick 19.

FIG. 54 shows a view of the first end 637 of the fourth stick 19.

FIG. 55 shows a view of the second end 638 of the fourth stick 19.

FIG. 56 shows a view of the fifth stick 20.

FIG. 57 shows a view of the first end 657 of the fifth stick 20.

FIG. 58 shows a view of the second end 658 of the fifth stick 20.

FIG. 59 shows a view of the second end 658 of the fifth stick 20.

FIG. 60 shows a view of the flipper assembly 687.

FIG. 61 shows a view of the flipper assembly 687.

FIG. 62 shows a view of the brick laying and adhesive applying head 32.

FIG. 63 shows a view of the first boom 12.

FIG. 64 shows a cut-away view of first boom 12 and second boom 14.

FIG. 65 shows a side view of the boom assembly 732 showing internalcable chains.

FIG. 66 shows a side view of the boom assembly 732 showing internalcable chains.

FIG. 67 shows a side view of the boom assembly 732 showing internalcable chains.

FIG. 68 shows a view of the stick assembly 744 showing extension cable.

FIG. 69 shows a view of the stick assembly 744 showing retraction cable.

FIG. 70 shows a view of the stick assembly 744 showing retractioncables.

FIG. 71 shows a view of the adhesive applicator 777.

FIG. 72 shows a view of the sliding chain 114.

FIG. 73 shows a view of a hollow chain link 778.

FIG. 74 shows a top view of straight guide 784.

FIGS. 75 and 75A each show a side view of the brick laying and adhesiveapplying head 32 and fifth stick 20.

FIGS. 76A-76E show side views of the foldable boom in various poses.

FIGS. 77A-77F show a sequence of a brick being transferred from thetower 10 to the T-B1 rotator 271 to first boom 12.

FIGS. 78A-78G show a sequence of a brick being transferred from thesecond boom 14 to the B2-S1 rotator 548 to the first stick 15. In theFIGS. 78A to 78G the foldable boom 732 is in a bent pose.

FIGS. 79A-79D show a sequence of a brick being transferred from thesecond boom 14 to the B2-S1 rotator 548 to the first stick 15. In theFIGS. 79A to 79D the foldable boom 732 is in a horizontal pose.

FIGS. 80A-80Q show a sequence of a brick being transferred from thefifth stick 20, to the S5-H flipper 687, having adhesive applied to thebrick, then the brick being transferred to the laying gripper 44 andbeing laid.

FIG. 81 shows a close up of the tower shuttle 186 at the top of tower10.

FIG. 82 shows a side view of first boom element 12 and in particular thetransfer of a brick from shuttle-B1 224 to shuttle-B2 531.

FIG. 83 shows a cut away view of part of the brick laying and adhesiveapplying head and showing the mounting of the brick laying head.

FIG. 84 shows a further view of part of the brick laying and adhesiveapplying head and showing the mounting of the brick laying head.

FIG. 85 shows a cut away view of part of the brick laying head.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIG. 1, a truck 1 supports a brick laying machine 2 whichis mounted on a frame 3 on the chassis (not shown) of the truck. Theframe 3 provides additional support for the componentry of the bricklaying machine 2 beyond the support that would be provided by a typicaltruck chassis. Referring also to FIG. 5, the frame 3 supports packs orpallets of bricks 52, 53. De-hacker robots can take rows of bricks offthe pallets and place them on a platform 51. A transfer robot can thenpick up an individual brick and move it to, or between either a saw 46or a router 47 or a carousel 48. The carousel is located coaxially witha tower 10, at the base of the tower 10. The carousel 48 transfers thebrick via the tower 10 to an articulated (folding about horizontal axis16) telescoping boom comprising first boom element in the form oftelescopic boom 12, 14 and second boom element in the form of telescopicstick 15, 17, 18, 19, 20. Each element 12, 14, 15, 17, 18, 19, 20 of thefolding telescoping boom has a shuttle located inside on alongitudinally extending track in the element, to transport a brickalong the longitudinal extent of the element. The bricks are movedthrough the inside of the folding telescoping boom by the linearlymoving shuttles. The shuttles are equipped with grippers that pass thebrick from shuttle to shuttle. Referring to FIG. 4, elements 15 and 17are shown, showing tracks 25 supporting shuttle 26 running along thelength of element 17, and showing tracks 29 supporting shuttle 30running along the length of element 15. Shuttle 26 has jaws 27 andshuttle 30 has jaws 31, which alternately can grip a brick 298. When theshuttles 27 and 30 are coincident both sets of jaws 27 and 31 can gripthe brick 298 as the brick is passed from one shuttle 26 to the othershuttle 30.

The end of the boom is fitted with a brick laying and adhesive applyinghead 32. The brick laying and adhesive applying head 32 mounts by pins(not shown) to element 20 of the stick, about an axis 33 which isdisposed horizontally. The poise of the brick laying and adhesiveapplying head 32 about the axis 33 is adjusted by double actinghydraulic ram 35, and is set in use so that the base 811 of a clevis 813of the robotic arm 36 mounts about a horizontal axis, and the trackercomponent 130 is disposed uppermost on the brick laying and adhesiveapplying head 32. The brick laying and adhesive applying head 32 appliesadhesive to the brick and has a robot that lays the brick. Vision andlaser scanning and tracking systems are provided to allow themeasurement of as-built slabs, bricks, the monitoring and adjustment ofthe process and the monitoring of safety zones. The first, or any courseof bricks can have the bricks pre machined by the router module 47 sothat the top of the course is level once laid.

For ease of understanding, headings will be used in the followingdiscussion.

Truck

Referring again to FIG. 1, a vehicle in the form of a rigid body truck 1is used as a base for the automated brick laying machine 2. In thepreferred embodiment the truck 1 is a 8×8, 8×6 or 8×4 rigid body truckmanufactured for example by Volvo, Mercedes, Iveco, MAN, Isuzu or Hino.The truck has a typical driver's cabin 54. In an alternativearrangement, a semi-trailer intended for connection to a prime moverusing a fifth wheel, may be used instead of a rigid body truck. Thebrick laying machine 2 could be mounted on a trailer, but this removesthe convenience of having it truck mounted.

Frame

A frame 3 forming a rigid chassis is mounted to the truck. The frame 3supports a pair of forward legs 4 and a pair of aft legs 5, one of eachpair on each side of the truck. The legs 4 and 5 can telescopicallyextend outwardly, and hydraulic rams then push down feet 6 to providestability to the automated brick laying machine 2. In practice, thehydraulic rams will adjust by positioning the feet 6 so that the frame 3and hence the rigid body truck 1 is positioned horizontally. Thisresults in correct vertical alignment of the vertical axis 9 and thetower 10 which are described hereafter. It follows then, that thiscorrect alignment ensures that, subject to deflection tolerances, theaxis 33 at the end of the element 20 is horizontal, and then withcorrect adjustment of the poise of the brick laying and adhesiveapplying head 32 by the ram 35, the base 811 of a clevis 813 of therobotic arm 36 mounts about a horizontal axis, and the tracker component130 is disposed uppermost on the brick laying and adhesive applying head32.

An enclosure 7 forming an outer body is mounted to the frame 3. Theenclosure 7 provides some weather protection, noise isolation andguarding of moving parts. Referring to FIGS. 1, 2 and 6, the enclosure 7is fitted with a pair of doors 85, 86 that are open when the boom 12 andstick 15 are folded. When the boom 12 and stick 15 are unfolded, the topdoors 85, 86 are closed by moving door 85 to the right 87 and door 86 tothe left 88 to provide a first level of rain protection and noiseisolation.

Referring to FIGS. 2, 4, 5, the frame 3 supports a fold down platform 8at its rear end. The fold down platform 8 is mounted at its lowermostextent to the frame 3 on hinges and is moved by electric or hydraulicrams (not shown) from the raised vertical position illustrated in FIG. 2to the lowered horizontal position shown in FIG. 4. The fold downplatform 8 is provided, when it is in the horizontal position, toreceive packs of bricks 52, 53 that are placed on it by a telehandler orfork lift truck.

Layout

Referring to FIG. 5, the frame 3 has a brick saw module 46 mounted onthe left hand side of the central longitudinal axis of the truck 1, andhas a router module 47 mounted on the right hand side of the centrallongitudinal axis of the truck 1. Reference to left hand side and righthand side is in the same context as used with reference to a vehiclebeing left hand drive or right hand drive. The frame supports a carousel48 in the center of the frame, located toward and behind the driver'scabin 54 of the truck 1. The frame has a chute 76 located to the rightof the transfer platform 51, for disposal of reject bricks.

The invention could be arranged in a mirror image about the verticalcentreline without deviating from the inventive concepts described.

Referring also to FIG. 8, the enclosure 7 has an enclosure frame 63. Theenclosure frame 63 supports a programmable brick handling apparatus inthe form of a transfer robot 64.

Services

A large capacity electric generator (not shown) is mounted to the truck1 chassis or the frame 3 and is driven by the IC engine (not shown) ofthe truck 1. The generator provides power to the electrical system ofthe automated brick laying machine 2.

Referring to FIG. 5, the frame 3 supports a dust extraction system 79.The frame 3 also supports a refrigerated liquid coolant refrigerator 83and pump 84. The liquid coolant system 85 is used to cool electroniccomponents and electric motors (not shown). The frame 3 also supports anelectrical and controls cabinet 82.

Scraper

Referring to FIG. 5, the frame 3 supports a first scraper 55 and asecond scraper 56. The scrapers are provided to shift packs of bricksplaced on the fold down platform 8 onto a first de-hacker bay 49 and asecond de-hacker bay 50 located on the rear of the frame 3, immediatelyadjacent the fold down platform 8.

Each scraper 55, 56 has an extending arm 57 that moves out past thebricks on the fold down platform 8 and then is lowered and then thefirst scraper 55, drags the first pack of bricks from the fold downplatform 8 into the first de-hacker bay 49.

Alternatively, a single scraper not shown could be provided with an armthat swings to a side or the opposite side to be able to drag bricksfrom either de-hacker bay.

Transfer Platform

The frame supports a transfer platform 51, immediately forward of thefirst de-hacker bay 49 and the second de-hacker bay 50. The transferplatform 51 is provided to temporarily place bricks for furtherprocessing.

De-Hacker

In typical operation, a first de-hacker bay 49 is loaded with externalbricks 52 that may be used for the external walls of a structure beingbuilt. The second de-hacker bay 50 is loaded with internal bricks 53that may be used for the internal walls of the structure being built, ina double brick style construction. Either de-hacker bay 49, 50 may beloaded with any type of bricks that are to be used for a structure beingbuilt, since the placement of the bricks is a matter for programming. Ina single brick construction where internal framework is to be addedmanually afterwards, both de-hacker bays would accommodate the same typeof brick. It should be noted that the present invention enablesconstruction of brick walls significantly faster and usually at a costbelow that of internal framed walls, so in most applications, thepresent invention would be used to build all of the walls of astructure.

Referring to FIG. 7, each de-hacker bay 49, 50 is provided with a fiveaxis Cartesian de-hacker robot 58 fitted with a gripper 59 to pick up abrick or a row of bricks. Each de-hacker bay 49, 50 is provided with acamera 60 for a machine vision system 61 to measure the position andlocation of the top layer of bricks not shown in the de-hacker bay 49.The machine vision system 61 may also detect defects in the bricks. Thebi-rotary wrist 62 of the de-hacker robot enables bricks to be grippedand then re oriented. It also allows brick packs to be oriented ineither direction and to correct for mis-alignment. For example, bricksthat are packed laying down can be stood up before they are placed onthe transfer platform 51.

Each de-hacker robot 58 can pick up a row of bricks from a pack ofbricks, or pick up a single brick, and move it to the transfer platform51.

Transfer Robot

Referring to FIG. 5 and FIG. 8, the transfer robot 64 moves a brickbetween the transfer platform 51 and optionally to or from the saw 46and/or router 47, to the carousel 48, or optionally to the chute 76.

Additionally, referring to FIG. 16, the transfer robot 64 picks upsingle bricks 65 from the transfer platform 51. The transfer robot 64 isa Cartesian robot with five axes and a gripper 66 fitted to it. Thetransfer robot 64 has longitudinal rails 67, 68 mounted above the sawand router and fastened to the enclosure frame 63. The transfer robot 64has a transverse gantry 158 which slides in a longitudinal direction 69.The gantry 158 slideably supports a carriage 153 that movestransversely, the carriage 153 slideably supports a tee column 151 thatslides vertically. The tee column 151 slideably supports a carriage 152that slides longitudinally. The tee column 151 allows the carriage 152and the bi rotary wrist 154 to be moved beyond the longitudinal positionthat could be reached by a wrist not shown mounted directly to avertical column not shown in place of the tee column 151. The carriage152 supports a bi rotary wrist 154 that can slew and tilt the gripper66.

The transfer robot 64 may perform a number of operations. Mostfrequently the transfer robot 64 picks up a brick 65 from the transferplatform 51 and delivers it to a gripper mounted on a carousel 48 whichcan rotate around a slewing ring 11. Alternatively, the transfer robot64 may pick up a brick 65 from the transfer platform 51 and deliver thebrick 65 to the table 70 of the saw module 46. Alternatively, thetransfer robot 64 may pick up a brick 65 from the transfer platform 51and deliver it to the gripper 72 of the router module 47. Alternatively,the transfer robot 64 may pick up a cut brick 73 from the saw module 46and transfer it to the gripper 74 of the carousel 48. Alternatively, thetransfer robot 64 may pick up a brick 65 from the router 47 and move itto the gripper 74 of the carousel 48. Alternatively, the transfer robot64 may pick up a brick off cut 75 or broken or damaged brick and deliverit to a brick rejection chute 76 (shown in FIG. 5). The brick rejectionchute 76 may optionally be fitted with a brick crushing device to reducethe volume of brick waste.

Saw

Refer to FIGS. 26, 27, 28, 29 for details of the saw 46 module. The sawmodule 46 has a rotating blade 93 mounted from its base 300. A slidingtable 70 supports a brick and moves the brick against the saw. The brickis held to the table 70 by a clamp assembly shown generally in FIGS. 28and 29. For compactness, the clamp moves up and down 99 and also backand forth 96 so that it can be moved forward when a brick is beingplaced onto the table or picked up by the transfer robot. For smoothmotion the table is supported on linear guide rails 301, 302, 303, 304and moved by a servo motor and belt assembly. A detailed descriptionfollows.

Table

Referring to FIG. 27 in particular, the saw 46 has a base plate 300,which is supported on the frame 3. The base plate 300 is fitted withlinear guides 301, 302, 303, 304. The linear guides 301, 302, 303, 304respectively support bearing cars (not shown) which support the movingtable 70. The moving table 70 is fitted with a drive bracket 310. Thebase plate 300 supports a gearbox 305 which supports a servo motor 306.Servo motor 306 drives the input of the gearbox 305. Gearbox 305 has anoutput shaft (not clearly visible) which is fitted with a pulley 307.The base plate 300 supports an idler pulley 308. A toothed belt 309 iswrapped around pulleys 307 and 308 with its ends fastened to the drivebracket 310. The servo motor 306 drives the gearbox 305 which drives thepulley 307 which drives the belt 309 which moves the table 70 to apredetermined position in which a brick is to be cut, and through theblade 93 to complete a cutting operation.

Saw Blade

The base plate 300 supports a bracket 311 which supports a motor 312which drives a pulley 313. The base plate supports a bearing housing314. The bearing housing rotatably supports a shaft 315. The shaft 315has a saw blade 93 fastened to it and a pulley 316 fitted to theopposite end of the shaft 315. A belt 317 wraps around pulleys 313 and316. The motor 312 drives pulley 313 which drives belt 317 which drivespulley 316 which turns shaft 315 which rotates the saw blade 93. The sawblade 93 rotates about a horizontal axis 95 transverse to the truck 1.

The saw mechanism could be replaced with a band saw, reciprocating saw,a vibrating saw or a chain saw.

Clamp

Referring to FIG. 27, the moving table 70 is fitted with a clampingmechanism 94 for the clamping of bricks. The moving table 70 supports acolumn 318, on which the clamping mechanism 94 is placed. Referring toFIG. 28, the column 318 supports a top plate 319 and a lower bearinghousing 324 which supports a bearing 325. Top plate 319 supports a servomotor 320 to drive a vertical leadscrew 323. Servo motor 320 is fittedwith a toothed pulley 321. The top plate 319 provides a housing for abearing 322 which rotatably supports a vertical lead screw 323 at itstop end and the bottom end of the leadscrew 323 is supported by thebearing 325 in the lower bearing housing 324. The leadscrew 323 isfitted with a pulley 326. An endless toothed belt 327 is wrapped aroundpulleys 321, 326. Referring to FIG. 29 and FIG. 28, column 318 supportsa vertically disposed linear guide 328. Linear guide 328 supports abearing car 329 for vertical movement therealong. The bearing car 329supports a mount plate 330 which supports a bearing car 331 and leadscrew nut 342. Lead screw nut 342 is engaged with lead screw 323.Bearing car 331 supports a clamp frame 332 for horizontal movement.

Servo motor 320 rotates pulley 321 which moves belt 327 to drive pulley326 which rotates the leadscrew 323 to vertically move the clamp frame332. Referring additionally to FIG. 9 and FIG. 27, the clampingmechanism 94 has a first linear axis 96 parallel to the truck 1longitudinal axis and this allows the clamping jaws 97 to be movedhorizontally so that the transfer robot 64 can access a brick on thetable 70. The clamping mechanism 94 has a second vertical axis 99 thatallows the clamping jaws 97 to be moved down toward the table 70 (downthe column 318) to clamp the brick 98 to the table 70.

Refer to FIG. 29, clamp frame 332 is provided with a slot 333 to allowit to pass the saw blade 93 (shown in FIG. 27). Clamp frame 332 isfitted with rubber pads 334, 335, adjacent to the sides of the slot 333,so that the rubber pads 334, 335 may contact and securely clamp to thetop face of a brick 98 (shown in FIG. 9). Referring to FIG. 28, clampframe 332 supports a gearbox 336 which supports a servo motor 335′.Servo motor 335′ drives the input of the gearbox 336. The output of thegearbox 336 is fitted with a pulley 337. Clamp frame 332 supports idlerpulleys 338, 339,340. Mount plate 330 supports a belt clamp plate 341. Atoothed belt 342′ wraps around pulleys 337, 338, 339, 340 and is clampedat both ends by belt clamp plate 341 to mount plate 330. Servo motor335′ drives the gearbox 336 to rotate the pulley 337 which moves thetoothed belt 342′ to move the clamp frame 332 horizontally relative tothe column 318.

Cable Chains

Cable chains are used to route power and signals to the servo motors.

Column 318 supports a cable bracket 343. A cable chain 344 has its firstend 348 fastened to the enclosure 100 (shown in FIG. 26). Cable bracket343 at its top end supports the second end of cable chain 344. Cablebracket 343 also supports a first end of a cable chain 345. Mount plate330 supports a cable bracket 346. Referring to FIG. 29, the second endof cable chain 345 is fastened to cable bracket 346. Cable bracket 346supports a first end of a cable chain 347. The second end of cable chain347 is fastened to the clamp frame 332. Electrical cables are routedthrough cable chain 344 to servo motor 320 and then through cable chain345 and 347 to servo motor 335′ (shown in FIG. 28).

Enclosure

Referring to FIG. 26, an enclosure 100 is provided around the saw tocontain dust. The enclosure 100 has an opening door 354 to allow thedelivery or removal of a brick by the transfer robot 64. The openingdoor 354 slides back and forth along linear guides 348 and 349.

The base plate 300 is provided with an enclosure 100. Enclosure 100, onits top, supports linear guide 348 and on its inner side it supportslinear guide 349. Linear guide 348 slideably supports bearing cars 350,351, (shown as hidden lines in FIG. 26). Linear guide 349 slideablysupports bearing cars 352, 353 (shown as hidden lines in FIG. 26).Bearing cars, 350, 351, 352, 353 support a door 354. Enclosure 100,supports a motor mount plate 356 to support a servo motor 355. Servomotor 355 is fitted with a pulley 357. Enclosure 100 also supports anidler pulley 358. A belt 359 is wrapped around pulleys 357, 358. Theends of belt 359 are fastened to the door 354 with a clamp plate 360.Servo motor 355 drives pulley 357 which moves the belt 359, which movesthe door 354.

When the door 354 is in its closed position 361, the door 354 containsbrick dust and noise within the enclosure 100. When the door is in anopen position 362, it allows access for the transfer robot 64 to reachinside the saw 46 to place a brick 73 on the moving table 70. The sawblade 93 rotates partially within a guard and dust extraction hood 101(also shown in FIG. 9) that is connected to a pipe 102 that is connectedto the dust extractor 79 (see FIG. 5).

Router

Refer to FIGS. 30, 31, 32, 33, 34, 35, 36, 37, 38 for details of therouter module 47.

5 axis CNC routers and 5 axis CNC machining centers are known inengineering and manufacturing. The router module 47 of the embodimenthas a layout that is particularly compact in relation to the size of thebrick being machined and compact in relation to the travel of thespindle. The layout of the router 47 has the advantage that the toolmagazine 391 is easily accessed from the side of the truck 1. The routerhas the advantage that the brick gripping mechanism 72 (see FIG. 34) isintegrated directly onto the rotary orientation mechanism. A hopper 80(see FIG. 30) is provided to collect brick dust and direct it towards adust extraction suction hose. Moving parts of the router tool 90 arescreened to isolate them from brick dust which may be abrasive and causewear of machine parts.

Referring to FIG. 30, to obtain a narrow width of the router module 47,the tool magazine 391 of the router module 47 is mounted concentricallywith the trunnion axis 454 (see FIG. 34), between the rotary orientationassembly 366 (see FIG. 31) trunnion 414 and the trunnion support 392. Inprior art machining centres or routers, the tool magazine 391 is mountedon the outside of the trunnion support, thus requiring further travel ofthe router to reach the magazine, or the addition of a tool change armnot shown to transfer tools from the magazine to the spindle of therouter. The advantage of the present invention is that having thetrunnion support outside of the tool magazine, means the tool magazineis close to the working area of the spindle and the trunnion support islocated beyond the reach of the spindle axis, but within a width of themachine that is required for clearance to spindle components.

Referring to FIG. 33, the router enclosure 364 is provided with a reardoor 388 and a top door 373 to provide a large single opening for thepassage of bricks to and from the router module 47. The transfer robot64 is located just above the router module 47. Due to height limitationsof the layout configuration, there is not room above the router module47, below the transfer robot 64 to place a brick in through a topopening door 373. The brick must be transferred in from the opening ofthe rear door 388. The brick is supported from above by the transferrobot 64. The top door 373 provides an opening above the brick so thatthe transfer robot 64 can support the brick from above, once the brickis maneuvered to the orientation assembly 366 (see FIG. 31).

Referring to FIGS. 30, 31 and 32, the router module 47 has a base 363.The base 363 supports an enclosure 364 to contain dust, the toolmagazine 391 for holding routing and milling tools, a 3 axis motionassembly 365 (see FIG. 31) for moving the router tool spindle 90 (seeFIG. 32) to a desired cutting position, and the orientation assembly 366(see FIG. 31) to rotate and tilt the brick.

A detailed description of the router follows, with reference to FIGS.10, 30, 31, 32, 33, 34, 35, 36, 37 and 38.

The router module 47 has a router base 363 supporting the tool changecarousel in the form of the tool magazine 391 that can hold up to 24router bit tools. The router module 47 has a tilting rotary table 366,shown generally in FIGS. 34 and 35, which is fitted with an electricscrew actuated gripper 434, 435. Referring to FIG. 10, the router module47 is fitted with the enclosure 364 to contain dust and noise. Therouter module 47 is fitted with a dust hopper 80. The hopper 80 isprovided with a dust extraction pipe 81 at its base. The dust extractionpipe 81 is connected to the dust extractor 79.

Refer to FIG. 31. The router tool 90 has three orthogonally moving axes,X 709, Y 710 and Z 711.

As can be seen in FIG. 5, the router 47 is arranged to provide clearanceto the folded boom and laying head when they are in the folded transportpose.

Enclosure

A detailed description of the enclosure 364 follows. Refer to FIGS. 30and 33. The enclosure 364 has a sliding door 373 on top thereof and asliding rear door 388, both provided for placing and removing a brickfrom the router, the brick entering via the opening of the rear door,with the top door opening providing access for the transfer robot.Enclosure 364 supports linear guides 367, 368. Linear guide 367 supportsbearing cars 369, 370, and linear guide 368 supports bearing cars 371,372. Bearing cars 369, 370, 371, 372 support door 373. Enclosure 364supports a drive mount plate 520. Drive mount plate 520 supports agearbox 374 (see FIG. 30). Gearbox 374 supports a servo motor 375. Servomotor 375 is fixed to a large pulley 376. Large pulley 376 is fixed to asmall pulley 377. Enclosure 364 supports an idler pulley 378. A belt 379wraps around pulleys 376 and 378 with its ends fixed to the door 373 bya clamp plate 379.

Referring to FIG. 33, enclosure 364 supports an idler 380. Base 363supports a back plate 381. Back plate 381 supports linear guides 382,383. Linear guide 382 supports bearing cars 384, 385. Linear guide 383supports bearing cars 386, 387. Bearing cars 384, 385, 386, 387 supportrear door 388. Rear door supports bracket 389. Referring to FIG. 30, abelt 390 wraps around pulleys 377 and 380 with its ends fixed to bracket389 by a belt clamp 390.

Referring to FIG. 30, servo motor 375 drives gearbox 374 which rotatespulleys 376, 377 that move belt 379 and belt 390. Belt 379 moves door373 horizontally to open and close the top of enclosure 364. Belt 390moves rear door 388 (see FIG. 33) vertically to open and close the rearend of enclosure 364. The top door 373 and rear door 388 movesimultaneously.

Tool Magazine

Referring to FIGS. 30 and 31, the base 363 supports tool magazine 391,on an upstanding column 392 that also forms part of the trunnion for theorientation assembly 366 (shown in FIG. 31). The tool magazine 391 canrotate tool grippers 397 to present them in a position so thattoolholders 398 can be exchanged with the spindle 510, thereby allowingdifferent shaped cutting tools 399 to be used by the router, or a bluntcutting tool 399 to be replaced with sharp cutting tool 399. Cuttingtools 399 may be routing or milling tool bits or abrasive coated cutterssuch as diamond router bits.

Referring to FIG. 30, the base 363 supports the column 392, whichsupports bearing 393. Bearing 393 rotatably supports stub shaft 394.Stub shaft 394 concentrically supports bearing 395. Bearing 395 supportswheel 396. Wheel 396 supports a plurality of tool grippers 397. Toolgrippers 397 hold tool holders 398. In the preferred embodiment the toolholders 398 are BT30 or IS030 tool holders. Each tool-holder 398 holds acutting tool 399, which will typically be a tungsten carbide insertmilling or routing cutter. The cutters could alternatively be abrasivegrit coated cutters of tungsten carbide, diamond or CBN. Ceramic or CBNinserts could be used in place of tungsten carbide inserts.

Base 363 supports a servo motor/gearbox assembly with a small pulley(indicated generally at 400). Small pulley forms a reduction drive witha large toothed pulley 405 driven by a toothed belt 406. The largetoothed pulley 405 is fixed to the wheel 396 of the tool magazine 391 sothat the servo motor assembly 400 can move belt 406 which then rotatesthe wheel 396, thereby presenting different tool-holders 398 to a tooltransfer position 407 (shown in FIG. 31).

Orientation Assembly

Refer to FIG. 31. The orientation assembly 366 can grip a brick androtate and tilt it to present the brick in any orientation for machiningby the router. Referring to FIG. 34, which shows a close up of theorientation assembly 366, the brick is held in clamp jaws 434 and 435which can be rotated and also tilted by a trunnion 414.

Referring to FIG. 31, orientation assembly 366 is provided with a frame408 supported by base 363. Referring to FIG. 32, the frame 408 supportsservo motor 409 and bearing reducer 410. Bearing reducer 410 is drivenby an endless toothed belt 411 driving toothed pulley 412. Bearingreducer has an output plate located along horizontal trunnion axis 454(shown in FIG. 34). Servo motor 409 rotates the trunnion 414 oforientation assembly 366 about the horizontal trunnion axis 454.

Refer to FIG. 34 and FIG. 35. Trunnion 414 is built as a framecomprising a first end 425 with an end plate 415, welded to a top plate416 and a bottom plate 417, a front plate 418 and a rear plate 419. Topplate 416 is welded to a vertical plate 420 at the second end 424 (awayfrom the first end 425). At the second end 424, top plate 416 is weldedto vertical plate 420 and front plate 418 and rear plate 419. End plate423 is welded to bottom plate 417 and front plate 418 and rear plate419. A curved cover plate 422 covers the void between plates 420 and423, which contains a servo motor 451. Plate 423 closes the second end424 of the trunnion 414.

Refer to FIG. 35. Top plate 416 supports a bearing reducer 426. Bearingreducer 426 is fitted with a toothed pulley 427 at one end and a spacer428 at the other end. The spacer 428 supports a gripper base 429. Referto FIG. 34. Gripper base 429 supports linear guides 430, 431 whichsupport bearing cars 432 and 433 respectively. Bearing car 432 supportsjaw 434 and bearing car 433 supports jaw 435. Jaws 434, 435 support aplurality of rubber pads 436 to aid in gripping a brick. Jaw 434 isfitted with a lead screw nut 437 and jaw 435 is fitted with a leadscrewnut 438 (shown in hidden lines). Base 429 supports a bearing housing440. Base 429 supports a servo motor 441. Servo motor 441 is fitted witha pulley 442. Base 429 supports idler pulleys 443, 444, 445. Bearinghousing 440 supports a bearing which supports a leadscrew 448. Leadscrew448 supports pulley 450. Leadscrew 450 engages lead screw nuts 437, 438.A belt 446 is wrapped around pulleys 442, 443, 444, 450, 445, and passesbetween base 429 and linear guide 430. Servo motor 441 rotates pulley442 which moves belt 446 which rotates pulley 450 which rotatesleadscrew 448 which moves the jaws 434, 435, together to clamp a brickor apart to release the brick.

Refer to FIG. 35. Trunnion 414 supports a servo motor 451 internally,under the cover plate 422. Servo motor 451 is fitted with a pulley 452.Endless toothed belt 453 is wrapped around pulleys 427 and 452. Servomotor 451 rotates pulley 452 which moves belt 453 which rotates pulley427 which drives the input of bearing reducer 426 which then via itsoutput rotates the base 429 of the gripper 72.

Refer to FIG. 32. Servo motor 409 rotates pulley 411 which moves endlessbelt 414 which rotates pulley 413 which drives bearing reducer 410 whichrotates trunnion 414.

Referring to FIG. 35 spacer 428 supports a cable tube 455. Cables 456are routed through the trunnion 414, then through the cable tube 455,(refer to FIG. 34) through the groove 456, under linear guide 430 toservo motor 441.

It can be seen that the orientation assembly 366 rotates the trunnion414 and therefore a brick 180 degrees through the trunnion axis 454 topresent three adjacent faces of the brick oriented 90 degrees apart,while the base 429 can rotate the gripper through 180 degrees.

3 Axis Motion Assembly

Refer to FIGS. 31, 32, 36, 37 and 38. Referring to FIG. 31, the 3 axismotion assembly 365 moves the router tool 90 spindle motor 510 so thatthe spindle can machine a brick held in the gripper 72. Linear guidesand bearing cars such as Hiwin HGW or THK SHS series are used to providesliding connections along the three axes. The 3 axis motion assembly 365is moved by servo motors driving ball-screws through toothed belts.Movement could alternatively be provided by servo motors driving toothedbelts, pinions engaged with racks, or by direct drive linear motors orother suitable means.

The 3 axis motion assembly 365 has a moving column 463 which can movefrom side to side along the x-axis 709. The moving column 463 supports acarriage 480 which can move up and down along the y-axis 710. The movingcarriage 480 supports a ram 487 which can move back and forth. The ram487 supports the spindle motor 510, which holds and rotates the cuttingtool 399. The described 3 axis motion assembly provides rigid support ofthe spindle motor 510 and a very compact arrangement relative to thetravel.

A detailed description of the 3 axis motion assembly 365 follows,referring to FIGS. 31 and 32. Base 363 supports linear guides 457, 458.Linear guide 457 supports bearing cars 459, 460 (see FIG. 32) and linearguide 458 supports bearing cars 461, 462 (see FIG. 32). Bearing cars459, 460, 431, 462 support moving column 463. Moving column 463 supportsa ball nut 464 which engages with a ball screw 469. Base 363 supports athrust bearing assembly 473 which secures an end of the ball screw 469.Base 393 supports a mount block 465 (see FIG. 32) having a bearing 468to support the other end of the ball screw 469. The mount block 465supports a servo motor 466 fitted with a toothed pulley 467 which drivesa pulley 471 (see FIG. 32) fitted to the ball screw 469 via an endlesstoothed belt 470. As ball-screw 469 is engaged with ball nut 464, servomotor 466 translates moving column 463 along the x-axis 709.

Referring to FIG. 36, moving column 463 supports linear guides 474, 475.Linear guide 474 slideably supports bearing cars 476, 477, and linearguide 475 slideably supports bearing cars 478, 479. Bearing cars 476,477, 478, 479 support carriage 480 shown in FIG. 37. Moving column 463supports mount block 481 on which is mounted a servo motor 482 whichdrives a pulley 483. Mount block 481 supports a thrust bearing 484 whichsupports a ball screw 485 at the lower end thereof. The ball screw 485is supported at its upper end on a thrust bearing assembly 487. Theball-screw 485 has a toothed pulley 490 which is driven by an endlesstoothed belt 491 connected with toothed pulley 483.

Referring to FIG. 37, carriage 480 supports a mount block 488 which hasa ball nut 489 which engages with ball-screw 485 (shown in FIG. 36).Refer to FIG. 36. Servo motor 482 rotates pulley 483 which moves belt491 which rotates pulley 490 which rotates ball-screw 485 whichtranslates ball nut 489 which translates carriage 480 in a verticaldirection along the y-axis 710 (see FIG. 31).

Refer to FIGS. 37 and 38. Referring to FIG. 37, carriage 480 supportsbearing cars 490 (shown as hidden lines), 491, 492 and 493 (shown ashidden lines). Bearing cars 492 and 493 slideably support linear guide494, and bearing cars 490, 491 slideably support linear guide 495.Linear guides 494, 495 support ram 487. Carriage 480 supports strut 496.Strut 496 supports bearing housing 499. Bearing housing 499 supportsbearing 500. Carriage 480 supports mount block 502. Mount block 502supports servo motor 503. Referring to FIG. 38, servo motor 503 supportspulley 506. Mount block 502 supports bearing 504. Bearing 504 andbearing 500 rotatably support ball-screw 505. Ball-screw 505 supportspulley 507. Endless belt 508 is wrapped around pulley 506 and pulley507. Ram 487 supports mount block 497. Mount block 497 supports ball nut498. Ball nut 498 engages with ball-screw 505. Servo motor 503 rotatespulley 506 which moves belt 508 which rotates pulley 507 which rotatesball-screw 505 which translates ball-nut 498 which translates ram 487along the z-axis 711.

Referring to FIG. 37, ram 487 has a bore 509. Ram 487 supports spindlemotor 510 shown in FIG. 38 in said bore 509. In the preferred embodimentthe spindle motor 510 is an off the shelf cartridge spindle motor, forexample HSD ES331. Spindle motor 510 has a conical taper 511 thataccepts and clamps to the tool holders 398 (see FIG. 30) by known means.

Cable Chains

Various servo motors and the spindle require the connection ofpressurised air hoses, electrical power cables and signal cables. Tosupport the hoses and cables, various cable chains are used. A detaileddescription of the support and routing of the cable chains follows.

Refer to FIGS. 31, 32, 37 and 38. Referring to FIG. 38, strut 496supports a bracket 512. Ram 487 supports a bracket 513. Bracket 512supports a first end of a cable chain 514. Bracket 513 supports a secondend of cable chain 514.

Refer to FIG. 31. Base 363 supports a first end of a cable chain 515.Moving column 463 supports a bracket 516 (Refer to FIG. 36 for a largerview of bracket 516). Bracket 516 supports a second end of cable chain515. Refer to FIG. 32. Bracket 516 supports a first end of cable chain517. Strut 496 supports a bracket 518. Bracket 518 supports a second endof cable chain 517 (FIG. 37 shows detail of bracket 518).

Refer to FIG. 31, 32, 37, 38. Referring to FIG. 32, cables and hoses(not shown for clarity) are routed from the base 363, through cablechain 515, then through cable chain 517 and then through cable chain514. Referring to FIG. 5, cables not shown connect electrical power andsignals from the control cabinet 82 to the servo motors 466 (see FIG.31), 482 (see FIG. 32), 503 (see FIG. 32) and the spindle motor 510 (seeFIG. 38). Referring to FIG. 38, ram 487 is provided with a hole 519 toprovide access for electric cables and hoses to spindle motor 510.

Vision System

A vision system is used to check that each brick handled by the transferrobot is of the correct size, shape, colour and texture and that anycuts, grooves or machining has been done correctly. The vision systemalso checks for cracks or large missing chips.

Refer to FIG. 8. The enclosure frame 63 supports machine vision cameras103, 104 on each side to view both sides of a brick 65 held by thetransfer robot. The frame 3 supports a third camera 157 (shown in FIG.4) to view the bottom of a brick 65 held by the transfer robot 64 andthe enclosure frame 63 supports a camera 105 to view the top of a brick65 held by the transfer robot. Note as drawn in the pose shown forclarity the brick 65 is not in the field of view of the machine visioncameras 103, 104, 105, 157. The enclosure frame supports laser lineprojectors 106, 107 that project structured light onto a brick 65 heldby the transfer robot 64. The machine vision cameras 103,104,105 scanthe 3D shape of the brick as it is moved by the transfer robot. Visionanalysis, using for example Halcon 12 software is used to form a 3Dmodel of the brick that is then compared to an expected 3D model of thebrick to check that it is the correct size, of acceptable quality andthat any saw cuts or routing cuts have been correctly made.

Volume scanners 108, 109 (shown in FIG. 6) are placed at the rear of thetruck 1 and enclosure 7 to ensure that no personnel enter a danger areasuch as the working envelope of the scrapers 55, 56 (see FIG. 5) or theinternal volume of the enclosure 7.

Carousel

Refer to FIGS. 1, 5, 8, 15 and 17. Referring to FIG. 1, the folding boom732 can be rotated about a vertical axis 9 to point in any directionaway from the truck. Referring to FIG. 8, the transfer robot 64 movesbricks to a location near the tower 10 (shown in FIG. 5) of the foldingboom 732 (shown in FIG. 1). Referring to FIGS. 1 and 5, the carousel 48receives bricks from the transfer robot, at a location approximately onthe centreline of the truck, behind the tower 10, and rotates about avertical axis 9 to line the bricks up with the rotated folding boom 732.

Referring to FIGS. 15 and 17, the carousel 48 receives bricks from thetransfer robot 64 and passes them to a tower shuttle 186 sliding on thetower 10. Referring to FIG. 15, the carousel has a ring frame 166 whichrotates around the tower 10 (shown in FIG. 17). The ring frame 166supports a gripper 74 that can tilt to receive a brick from the transferrobot 64 and then be rotated to line up with the tower shuttle 186. Adetailed description follows.

Referring to FIGS. 5 and 15, the frame 3 supports the carousel 48.Referring to FIG. 15, the frame 3 supports a ring guide 167 whichsupports a plurality of rollers 169 that in turn support the ring frame166 which is thus able to rotate about the vertical slewing axis 9. Thering frame 166 supports a bracket 170 that in turn supports an arm 165that rotates about a horizontal rotary axis 77. The arm 165 supports thegripper 74 which has jaws 171, 172 that move toward each other to hold abrick (not shown), or apart to release the brick. The ring frame 166 isrotated about the vertical axis 9 by a servo motor 173 and gearbox 174that drives a pinion 175 engaged with a ring gear 176 fixed to the ringguide 167. The bracket 170 supports a servo motor 177 that drives agearbox 178 which moves the arm 165. The arm 165 supports a servo motor179 and a lead screw 180. The servo motor 179 rotates the lead screw180. The jaws 171, 172 are respectively fitted with lead nuts not shownthat engage with the lead screw 180. The ring frame 166 supports a cableduct 185.

The frame 3 supports a cable guide 181. The cable guide 181 supports acable chain 182. The cable chain 182 is connected at a first end 183 tothe cable guide 181 and is therefore fixed relative to the frame 3. Thecable chain 182 has a second end 184 attached to the cable duct 185.Electric current carrying cables (not shown) that carry power andcontrol signals and sensor signals from the electric control cabinet 82,are routed via the frame 3, through the cable chain 182 to the cableduct 185 and then to the servo motors 173, 177, 179.

The carousel 48 can move the gripper 74 from a pickup position where itreceives a brick from the gripper 66 mounted on the transfer robot 64,and rotate to a drop off position where it deposits a brick to thegripper jaws 207, 208 on the tower shuttle 186 (shown on FIG. 17).

Tower

Refer to FIG. 5 and FIG. 17. The frame 3 supports a slewing ring 11 atits front end 78, located coaxially with the carousel 48. Refer to FIG.17. The slewing ring 11 supports a turret in the form of a tower 10. Thetower 10 can slew about the vertical axis 9 of the slewing ring 11. Thetower 10 supports the foldable boom 732 (shown in FIG. 1). The towersupports a tower shuttle 186 that moves bricks from the carousel 48 atthe bottom end of the tower to the foldable boom 732 at the top of thetower 10.

Refer to FIG. 17 and FIG. 81. The tower 10 supports two parallel spacedlinear bearing rails 189, 190. The linear bearing rails 189, 190respectively support four bearing cars 191 and 192 (and others occluded,not shown). The bearing cars 191, 192 support a tower shuttle car 193which in turn supports a gripper 194. The gripper 194 may grasp a brick195. The tower 10 supports a servo motor 196 which drives a toothedpulley 197 that engages with and drives a belt 198 that is connected to,and thereby drives the tower shuttle 186 in a vertical direction. Thetower 10 supports a servo motor 199 that drives a toothed pulley 200that engages and drives a toothed belt 201. Tower 10 supports an upperidler pulley 202. Toothed belt 201 wraps around upper idler pulley 202.The tower shuttle car 193 supports pulleys 203 and 204. The towershuttle car 193 supports a lead screw 206. Leadscrew 206 is connected toa pulley 205. The toothed belt 201 passes around pulley 203, then drivespulley 205 and thus drives the lead screw 206. The belt 201 passesaround pulley 204 and then returns to pulley 200. The tower shuttle car193 slideably supports gripper jaws 207, 208. Gripper jaws 207, 208support lead screw nuts (not shown) that engage leadscrew 206. Leadscrew206 moves jaws 207, 208 toward each other to grip a brick 195, and inthe opposite rotational direction, moves jaws 207, 208 apart to releasethe brick 195.

Refer to FIG. 17. The tower 10 supports a lug 209 with a bore 213 havinga horizontal axis 214, the bore receiving a fastener to connect an endof hydraulic ram 22 (shown in FIG. 1) to control the pose of the firstboom 12. Tower 10 supports clevis plates 210, 211 which have a bore 212with a horizontal axis 13, about which the near end of the first boom isattached for pivoting movement (shown in FIG. 1).

Boom

Refer to FIG. 1. The foldable boom 732 is articulated and telescopic sothat it can position the laying head throughout a large working volume,far from and close to the truck, both low and high so that the layinghead can reach all courses of the structure to be built, both near andfar, low and high. FIG. 76A shows the foldable boom 732 in a folded posefor transport. FIG. 76B shows the foldable boom 732 with the first boom12 raised and the stick assembly 744 vertical. FIG. 76C shows thefoldable 732 with the stick assembly 744 horizontal with the telescopicsections extended. FIG. 76C shows a pose that could be used to build amulti storey structure. FIG. 76D shows the foldable boom assembly 732with the first boom 12 raised above horizontal and the stick assembly744 lowered slightly below horizontal. FIG. 76E shows the foldable boom732 at its maximum extension with both the first boom 12 horizontal andthe stick assembly 744 horizontal.

The foldable boom 732 allows motion through a big envelope free ofsingularities and poles. A pole is a position within a robot's envelopethat requires rapid rotation of one or more robot joints to maintainconsistent orientation of the end effector, for the end effector to passalong a trajectory that passes through the pole. A singularity is aposition or orientation, or a set of positions and orientations withinthe envelope that cannot be reached, or where the joints of the robotbecome poorly behaved, unstable, or the joint positions are difficult tocalculate. Normal industrial robots typically complete the same taskover and over so that it is possible to design, or alter the trajectoryand robot pose to be free and clear of poles and singularities or topass through a pole with specified rotation of the pole axis. Theautomated brick laying machine however must be able to complete avariety of tasks and any particular structure will require the boom tomove through a large portion of its envelope, thus making a pole andsingularity free working envelope desirable.

Shuttles within each section of the boom transport a brick along theinside of the boom. Shuttles pass a brick from a previous shuttle to thenext. Rotators at each articulated joint of the boom move a brick fromone boom element to the next, passing the brick from a previous adjacentshuttle to the next adjacent shuttle.

The bricks are passed by the shuttles, through the inside of the boom.The bricks are moved through the inside of the boom so that the boomstructure contains the bricks and/or debris, in the unlikely event thata brick, or debris from a brick becomes loose from a shuttle. The boomstructure provides convenient support to mount shuttles opposite eachother. In the present invention within the telescoping elements of theboom and within the telescoping elements of the stick, the shuttles arealternately mounted above or below the brick, so that adjacent shuttlesmay move so that the grippers on the shuttles can both grasp a bricksimultaneously and thereby transfer a brick from one shuttle to thenext, without letting go of the brick. FIG. 82 shows a partial view ofthe inside of the first boom element comprising first boom 12 and secondboom 14, with shuttle-B1 224 gripping a brick 28 from below andshuttle-B2 531 gripping a brick from above. The invention couldalternately be arranged to support the shuttles from the sides of theboom. The invention could alternately be arranged to support theshuttles on the top of the boom, however it would then be desirable tofit an additional enclosure to boom to contain any dropped bricks ordebris and the overall size of the boom would be larger or lessstructurally stiff.

First Boom Element

Referring to FIGS. 1 and 17, the tower 10 pivotally supports a foldableboom on clevis plates 210 and 211 for rotation about horizontal axis 13.The foldable boom comprises a first boom element comprising first boom12 and telescoping second boom 14, and a second boom element comprisingstick assembly 744. First boom 12 can pivot about the horizontal axis 13at the top of the tower 10, and a sliding second boom 14 istelescopically able to slide within the first boom 12.

Second Boom Element

Referring to FIG. 1, the second boom element 744 is pivotally connectedabout a horizontal axis 16 by an element in the form of an articulatingfirst stick 15 to the distal end of the second boom 14. The axis 16 issubstantially parallel to the horizontal articulation axis 13 of thefirst boom.

A sliding second stick 17 is telescopically able to slide within thefirst stick 15. A sliding third stick 18 is telescopically able to slidewithin the second stick 17. A sliding fourth stick 19 is telescopicallyable to slide within the third stick 18. A sliding fifth stick 20 istelescopically able to slide within the fourth stick 19. Collectivelyfirst stick 15, second stick 17, third stick 18, fourth stick 19 andfifth stick 20 form a stick assembly 744 also referred to as the secondboom element.

The number of telescopic booms 12, 14 or sticks 15, 17, 18, 19, 20 couldbe altered without deviating from the inventive concepts described.Collectively the tower 10, booms 12, 14 and sticks 15, 17, 18, 19, 20form a foldable boom assembly 732.

First boom 12 has a first near end 269 and a second distal end 270 shownin FIG. 18. First boom 12 is connected to the tower 10 (shown in FIG.17) by a pin or pins not shown, through the bore 212, in clevis plates210 and 211, connecting through apertures in first boom located at itsnear end 269.

Lug 209 on the tower 10 is connected to the rod end of ram 22 by a pin(not shown). Ram 22 supports a trunnion mount 215 located a shortdistance along the first boom 12 from the near end 269. The trunnionmount 215 provides boom lift lugs 216, 217. The articulated joint 21 ofthe tower 10 to the boom 12 about axis 13 is moved by ram 22 powered byelectricity or hydraulics.

Rotator

Refer to FIG. 24 and FIG. 25. The tower 10 supports a brick rotatingmechanism in the form of T-B1-rotator 271. The T-B1-rotator 271 is usedtransfer a brick from the tower shuttle 186 to the first boom shuttle224 (shown in FIGS. 19, 21 and 77D). FIG. 77A shows the tower shuttle186 holding brick 298. FIG. 77B shows the brick held by the T-B1-rotator271 after receiving it from the tower shuttle 186. FIG. 77C shows theT-B1-rotator 271 moving to align itself with the first boom segment 12.FIG. 77D shows the T-B1-rotator 271 aligned with the first boom segmentand shuttle-B1 224 moving into position under brick 298. It should beunderstood that the boom will not necessarily be horizontal while thisprocess occurs. FIG. 77E shows the shuttle-B1 224 in position under thebrick 298. In this position the shuttle-B1 224 will grip the brick andthe T-B1-rotator 271 will release the brick. FIG. 77F shows the brick298 held by the shuttle-B1 224 moving up the first boom segment 12. FIG.77G shows the T-B1-rotator 271 moving into position to accept anotherbrick from the tower shuttle 186.

A detailed description of the T-B1-rotator follows.

Referring to FIG. 25, T-B1-rotator 271 has a bracket 272 which isfastened to the tower 10 (shown in FIG. 17). Bracket 272 supports aspacer 274 which supports a servo motor 273. Servo motor 273 drives apulley 275. Bracket 272 supports idler pulleys 276, 277 and a bearingreducer 278. Bearing reducer 278 is fitted with an input shaft 279 whichis fitted with a pulley 280 driven by servo motor 273 via an endlesstoothed belt 281 wrapped around pulleys 275, 276, 277 and 280. Arm 282is rotated by bearing reducer 278 about a horizontal axis 290.

Bearing reducer 278 supports an arm 282 having a plate 283 dependingtherefrom at right angles. Plate 283 supports linear guides 284, 285.Linear guides 284, 285 respectively support bearing cars 286, 287 whichrespectively support jaws 288, 289 provided to clamp a brick. Jaws 288,289 respectively are fitted with lead screw nuts 296, 297 shown ashidden lines. Leadscrew nuts 296, 297 engage with leadscrew 293.

Arm 282 supports a servo motor 291 (not shown clearly in FIG. 25, butshown in FIG. 24) which drives a pulley 292. Arm 282 supports aleadscrew 293 fitted with a pulley 294. An endless toothed belt 295 iswrapped around pulleys 292 and 294. Through this arrangement, servomotor 291 drives leadscrew 293 which is engaged with leadscrew nuts 296,294 to move jaws 288, 289 together to grip a brick 298 or apart torelease the brick 298.

As can be seen in the drawings, and particularly in the sequence ofFIGS. 77A to 77G, the brick 298 is transported up the tower 10 with itslongitudinal extent parallel with the vertical axis 9 of the tower 10.The tower shuttle 186 holds the brick 298 in its gripper jaws 207 and208 vertically above the body of the tower shuttle car 193, so that thebrick can be passed within reach of the jaws 288, 289 of T-B1-rotator271. The T-B1-rotator 271 rotates the brick 298 so that its longitudinalextent is aligned with the longitudinal extent of boom 12 (and 14). TheT-B1-rotator 271 rotates about the same horizontal axis 13 as first boom12 is mounted to the tower 10. The location of this horizontal axis 13is such that the shuttle-B1 224 is able to travel under the T-B1-rotator271 to allow the transfer of the brick 298 from T-B1-rotator 271 to theshuttle-B1 224.

First Boom

Refer to FIGS. 18, 19, 20. Referring to FIG. 18 first boom 12 has boomlift lugs 216, 217 welded thereto. Referring to FIG. 19, boom 12 is of asubstantially rectangular or box cross section, and is constructed bywelding bottom plate 218 to side plates 219, 220 which are welded to topplate 221. Removable panels (not shown) may be provided in convenientpositions along any of the plates 218, 219, 220, 221, to provide accessfor servicing of internal componentry within first boom 12. The bottomplate 218 supports a track in the form of channels 222, 223 (also shownin FIG. 18). Channels 222 and 223 support shuttle-B1 224. Referring toFIG. 18, shuttle 224 is shown gripping a brick 225.

Shuttle

A shuttle grips a brick and is moved along the inside of the boom fromthe near end of the boom, nearly to the distal end of the boom, bytoothed belts driven by servo motors fitted to the boom. The servomotors are fitted to the boom to minimise the size and weight of themoving shuttle and also to avoid having to use cable chains or sliptracks to transfer electrical power and signals to and from theshuttles. One servo motor 256 moves the shuttle and the other servomotor 255 moves the jaws of the shuttle. A detailed description follows.

Refer to FIGS. 18, 19 and 23. Referring to FIG. 23, bottom plate 218supports a drive assembly 254 located at the distal end 270 of the firstboom 12. Drive assembly 254 has a body that supports servo motors 255and 256. Servo motor 255 drives a pulley 258 which drives an endlessbelt 251. Endless belt 251 passes around idlers 260, 261. Plate 218supports idler pulley assembly 259 (shown in FIG. 18) to turn the belt.

Servo motor 256 drives a pulley 257. Drive assembly 254 has a shaft 262that supports a large pulley 263 and a small pulley 264, forming part ofa reduction drive. An endless toothed belt 258 wraps around pulley 257and large pulley 263. A belt 266 wraps around pulley 264 and idlerpulley assembly 265 at the near end 269 of first boom. Belt 266, runningthe length of first boom 12 is driven by pulley 264.

Refer to FIGS. 18, 21 and 22. Referring to FIG. 21, shuttle-B1 224 has abody 246 which supports wheels 226, 227, 228, 229 that rotate aboutsubstantially horizontal axes, and supports wheels 230, 231, 232, 233that rotate about axes in a vertical plane. Shuttle-B1 224 supportslinear guides 234, 235. Linear guides 234, 235 respectively supportbearing cars 236, 237 which respectively support jaws 238, 239. Jaw 238is provided with rubber gripping pads 240, 241 and jaw 239 is providedwith rubber gripping pads 242, 243. Jaws 238, 239 respectively supportlead screw nuts 244, 245 at the base thereof (shown in FIG. 22). Body246 supports bearing housings 247, 248 (shown in FIG. 22) which supporta leadscrew 249. Referring to FIGS. 21 and 22, leadscrew 249 is fittedwith a pulley 250, located between the bearing housings 247 and 248.Leadscrew 249 engages with leadscrew nuts 244, 245. Body 246 supportsidler pulleys 252, 253. Tooth belt 251, shown partially in FIG. 22 andalso in FIG. 23, wraps partially around pulley 252, then pulley 250 thenpulley 253. Tooth belt 251 drives pulley 250, which in turn rotatesleadscrew 249 which moves the jaws 238, 239. Belt 265 is connected tobody 246 at a first location 267 and a second location 268. The drivetrain described allows servo motor 255 to move the jaws 238, 239together to clamp a brick 225, or apart to unclamp a brick 225. Thedrive chain described allows servo motor 256 to move the shuttle-B1along the inside of first boom 12. Thus a brick 225 can be clamped by ashuttle-B1 224 and moved from the first end 269 of first boom 12 to thesecond end 270 of first boom 12 and then brick 225 (shown in FIG. 18)can be unclamped. As servo motor 256 moves the shuttle-B1 224 along theboom, servo motor 255 must be synchronised with servo motor 256 to avoidthe jaws 238 and 239 from inadvertent movement which could result in thebrick being released or over-tightening of the jaws, or the shuttle jawsbeing run past their intended travel limits.

It will be seen in the discussion that follows, that the tracks,shuttles and drive assemblies of sticks 15, 17, 18, and 19 follow thesame fundamental configuration as that of boom 12.

Winch

Winches and cables are used to move the telescopic sections of the boomand stick via a system of pulleys. The winch and cable system provides avery light weight means of moving the telescopic sections of thefoldable boom. It was found that electric ball screws or hydraulic ramsor toothed racks and gears could be used to move the telescopic sectionsof the boom, but these systems have a higher weight than the cable drivesystem described. The winch and cable system is detailed below.

Referring to FIGS. 19 and 63, side plate 219 supports a winch assembly713. Referring to FIG. 63, winch 713 winds cables 714, 715 thattelescopically move the second boom 14 relative to the first boom 12(shown in FIG. 1). Winch assembly 713 has bracket 716 and bracket 717supported on side plate 219. Bracket 717 supports bearing reducer 718which is driven by servo motor 719, providing a reduction drive forwinch drum 720. Bracket 716 supports a roller bearing 721 thatrotateably supports winch drum 720.

Side plate 219 supports idler pulleys blocks 722, 723, 724, 725. FIG. 64shows a view of the boom 12 with side plate 219 and bottom plate 218removed for clarity so that the second boom 14 can be seen more clearly.First boom 12 bottom plate 218 supports idler pulley blocks 728, 729,730, 731. Second boom 14 bottom plate 524 supports idler pulley blocks726, 727. Cable 714 passes in turn from the winch drum 720 to pulleyblock 722 then to pulley block 723, then pulley block 728 then throughpulley block 726 then pulley block 731 and then is fastened to thebottom plate 524 of second boom 14. Cable 714 passes in turn from thewinch drum 720 to pulley block 724, then to pulley block 725, then topulley block 729, then through pulley block 727 then through pulleyblock 730 and then is fastened to the bottom plate 524 of second boom14. The pulley blocks provide mechanical advantage so that a thin cablecan be used. Servo motor 719 rotates the input of bearing reducer 718which rotates the winch drum 720 which moves cables 714, 715 whichslides second boom 14 relative to first boom 12.

Wear blocks 799 formed from ultra high molecular weight polyethylene(UHMPE) or other suitable material, are secured to the distal end ofboom 12 and the near end of boom 14 to provide bearing surfaces for theelements to telescopingly slide. Wear blocks 799 of such material aredescribed throughout this description to provide bearing surfaces forthe telescoping parts of both the boom and the stick.

Second Boom

Referring to FIGS. 39, 40, 41, 42, 43, second boom 14 is of asubstantially rectangular or box cross section. Referring to FIG. 39,second boom 14 is constructed by welding bottom plate 524 to side plates521, 522, and welding side plates 521, 522 to top plate 523. As with thefirst boom 12, removable panels (not shown) may be provided inconvenient positions along any of the plates 521, 522, 523, 524, toprovide access for servicing of internal componentry within second boom14. Second boom 14 has a first near end 525 and a second distal end 526.Second distal end 526 supports lugs 527, 528. Referring to FIG. 40, topplate 523 supports channels 529, 530, which form a track to supportshuttle-B2 531.

Shuttle-B2 531 has jaws 532, 533 for the gripping of a brick. Top plate523 supports bracket assembly 534, which supports idler pulleys 535,536, 537. Bracket assembly 534 supports servo motors 538, 539. Servomotor 539 drives the jaws 532, 533. Servo motor 538 drives theshuttle-B2 531. Shuttle-B2 531 can move linearly from the first end 525to the second end 526 of second boom 14. The arrangement is the same asdescribed for the first boom 12 except that the servo motors 538 and 539are mounted externally on boom 14 to allow the channels 529 and 530 thatform the track within second boom 14 to extend from the near end 525, tothe distal end 526, so that the shuttle-B2 531 can traverse the entirelength of second boom 14.

Referring to FIG. 40, side plate 521 supports a boss 562. Boss 562 has abore 563. Bore 563 supports an end of dog bone link 156 seen in FIG. 1.

Refer to FIGS. 11, 42 and 43. An arrangement of energy chains 112 isprovided within the boom and stick assembly 141 to carry cables andhoses. Bottom plate 524 supports cable chains 563, 564, 565.

Rotator-B2-S1

The rotator-B2-S1 548 transfers a brick from the second boom shuttle tothe first stick shuttle. It can rotate to align with either the secondboom, or the first stick, to that the brick maintains orientation withits longitudinal extent extending with the first stick longitudinalextent, when the brick is transferred from the second boom 12 to thefirst stick 15. The rotator-B2-S1 548 has movable gripper jaws to graspthe brick. A detailed description follows.

Referring to FIGS. 42 and 44, bottom plate 524 supports Rotator-B2-S1548 from supporting bracket 540. Bracket 540 supports bearing reducer541, which supports servo motor 542. Bearing reducer 542 supports anassembly of arm 543 and base 544. Base 544 supports mount plate 547which supports servo motor 549. Base 544 also supports linear guides545, 546. Linear guide 545 supports bearing car 550 which supports jaw551. Linear guide 546 supports bearing car 552 which supports jaw 553.Mount plate 547 supports bearing 554 (see FIG. 42), which supportsleadscrew 555. Motor 549 has a toothed pulley 556, and leadscrew 555 hasa pulley 557, with endless toothed belt 558 wrapped around pulley 556and pulley 557. Jaw 551 supports nut 556′, and jaw 553 supports nut 559(shown with hidden lines in FIG. 44). Leadscrew 555 engages with nuts556′, 559. Servo motor 549 thus drives leadscrew 555 to move jaws 551and 553 together to clamp a brick, or apart to release a brick. Servomotor 542 rotates the input of bearing reducer 541. The output ofbearing reducer 541 rotates arm 543 about a horizontal axis 16, which isthe same axis as the articulated joint 23 connection of second boom 14to first stick 15. Thus arranged, rotator 548 can grasp a brick locatedin shuttle-B2 at the second end 526 of second boom 14 and transfer it toa shuttle-S1 located at the first end 561 of first stick 15.

Joint

Refer to FIG. 1. The articulated joint 23 of second boom 14 to firststick 15 about axis 16 is moved by a luffing ram 24 powered byelectricity or hydraulics and a first dog bone link 155 and a second dogbone link 156.

Refer to FIG. 45 and FIG. 46. Side plate 568 supports lug 586. Sideplate 569 supports lug 587. Side plate 568 supports boss 588. Lugs 586,587 respectively have concentric bores 589, 590. Bores 589, 590 are onaxis 16. Boss 588 has a bore 591. Bore 591 supports a pin not shown thatsupports an end of dog bone link 156.

First Stick

Refer to FIGS. 45, 46. First stick 15 has a first near end 561 and asecond distal end 566. First stick 15 is of a substantially rectangularor box cross section and welded plate construction, comprising a bottomplate 567, welded to side plates 568, 569, and side plates 568, 569welded to top plate 570. Side plate 568 supports lugs 574, 575 forconnecting an end of luffing ram 24 (shown in FIG. 1).

Stick Assembly

The stick assembly has telescopic sticks that can extend and retract.The extension and retraction is servo controlled. Each stick supportschannels that in turn support shuttles that move bricks from a firstnear end to the next stick. The shuttles move back and forth on trackswithin their respective sticks. The shuttles are provided with clamps,and can pass a brick along the stick assembly.

Stick Winch and Cables

The telescopic stick assembly is extended and retracted by a winch thatwinds cables that wrap around a system of pulleys to move the sticks.The winch is driven by a servo motor and bearing reducer. A detaileddescription follows.

Refer to FIGS. 45 and 68. Referring to FIG. 45, the top plate 570supports a winch 578. Winch 578 winds cables 579, 580 thattelescopically move the second stick 17, third stick 18, fourth stick 19and fifth stick 20 within and relative to first stick 15 (shown in FIG.68).

Winch 578 is mounted to top plate 570 by bracket 581 and bracket 582. Abearing reducer 583 is provided between servo motor 584′ and a winchdrum 584. Bracket 581 supports a roller bearing 585 (not visible) thatrotateably supports the winch drum 584, at the end thereof away from thebearing reducer 583. Top plate 570 supports pulley blocks 746, 747, 748,749, 750, 751.

FIG. 68 shows a view of the stick assembly 744. Second stick 17 supportspulley blocks 752, 753. Third stick 18 supports pulley blocks 754, 755.Fourth stick 19 supports pulley blocks 756, 757. Extension cable 580 iswrapped on winch drum 578 and then passes through pulleys 750, 751, thento second stick 17 pulley block 752, then to pulley block 753, then tothird stick 18 pulley block 754, then to pulley block 755, then tofourth stick 19 pulley block 756, then to pulley block 757, then to atermination 758 on fifth stick 20. Tension on cable 580 forces the stickassembly 744 to extend.

Referring to FIG. 69, retraction cable 579 is wrapped on winch drum 578and then passes through pulley blocks 746, 747, 748 and 749 and thenruns internally inside stick assembly 744 to termination 759 on fifthstick 20. Tension of cable 579 forces the stick assembly 744 to retract.

FIG. 70 shows a view of stick assembly 744. Cables 759, 760 and 761 actto keep the extension of each stick, relative to its neighbours,similar. Second stick 17 supports pulley block 762. First stick 15supports a termination 765 of first end 771 of cable 759. Cable 759passes through pulley block 762 and third stick 18 supports atermination 766 of second end 772 of cable 759. Third stick 18 supportsa pulley block 763. Second stick 17 supports a termination 767 of firstend 773 of cable 760. Cable 760 passes through pulley block 763. Fourthstick 19 supports a termination 768 of second end 774 of cable 760.Fourth stick 19 supports pulley block 764. Third stick 18 supports atermination 769 of first end 775 of cable 761. Cable 761 passes throughpulley block 764. Fifth stick 20 supports a termination 770 of secondend 776 of cable 761.

First Stick

Referring to FIGS. 45 and 46, the top plate 570 supports a track in theform of longitudinally extending channels 571, 572, inside the stick 15.Channels 571, 572 run from the first near end 561 of first stick 15,nearly to the second distal end 566, save room for the drive assembly592 at the end of the track, inside the first stick 15. Channels 571,572 slideably support shuttle-S1 573. Shuttle-S1 573 has jaws 576, 577provided to clamp a brick.

Top plate 570 supports drive assembly 592 inside first stick 15, in thesame manner as that of the first boom 12. Top plate 570 supports bracket593, which supports idler pulleys 594, 595, 596, 597. Servo motors notshown on drive assembly 592 move the shuttle-S1 573 along the top of andinside first stick 15 and can open and close jaws 576, 577 to grip orrelease a brick. Thus shuttle 573 can grasp a brick at first near end561 of first stick 15 and move it to or toward second distal end 566 offirst stick 15, then unclamp the brick not shown. The mechanism for thisfunctions in the same manner as that of the first boom 12 and itsshuttle. The jaws 576 and 577 each include a deviation 576′ and 577′which aligns with the bracket assembly 534 of second boom 14, to provideclearance to receive bracket assembly 534 at the distal end of secondboom 14, when the shuttle-S1 573 moves in to take a brick fromrotator-B2-S1 548 when second boom 14 and first stick 15 are aligned inline, as shown in FIG. 79C.

Second Stick

Refer to FIGS. 47, 48, 49. Referring to FIG. 47, second stick 17 has afirst near end 598 and a second distal end 599. Second stick 17 ishollow and internally supports a shuttle that moves bricks from thefirst near end 598 to or toward the second distal end 599.

Second stick 17 is preferably constructed from carbon fibre sandwichpanels for low weight. Alternatively, second stick 17 way be welded withmetal plates. Second stick 17 is of a substantially rectangular or boxcross section. Second stick 17 is constructed by welding or bondingbottom plate 600 to side plates 601, 602. Side plates 601, 602 arewelded or bonded to top plate 603. Bottom plate 600 supports a trackformed by longitudinally extending channels 604, 605. Channels 604, 605support shuttle-S2 606 for movement therealong. Shuttle-S2 606 has jaws607 and 608 to grasp a brick. Referring to FIG. 48, bottom plate 600supports bracket 609 which supports idler pulleys 610, 611, 612, 613.Referring to FIG. 49, bottom plate 600 supports drive assembly 614located at the distal end 599 of second stick 17, which moves belts 615and 616, in order to move shuttle-S2 606 (shown in FIG. 48) and open andclose jaws 607, 608, in the same manner as that of the first boom 12 andits shuttle. Thus shuttle-S2 can grasp a brick located at the first nearend 598 of second stick 17 and move the brick to or toward the seconddistal end 599 of second stick 17 and unclamp the brick. The secondstick 17 has a void in the top plate 603 at the near end 598 (shown inFIG. 48), which is opposite the track formed by channels 604 and 605.This allows the shuttle-S1 573 of the first stick 15 to line up abovethe shuttle-S2 606 to enable the clamps thereof to transfer a brick fromshuttle-S1 573 to shuttle-S2 606.

Third Stick

Refer to FIGS. 50, 51 and 52. Referring to FIG. 50, third stick 18 has afirst near end 618 and a second distal end 619. Third stick 18 ispreferably constructed from carbon fibre sandwich panels for low weight.Alternatively, third stick 18 may be constructed with welded metalplates. Third stick 18 is of a substantially rectangular or box crosssection. Third stick 18 is constructed by welding or bonding bottomplate 620 to side plates 621, 622. Side plates 621, 622 are welded orbonded to top plate 623. Referring to FIG. 51, top plate 623 supports atrack formed by longitudinally extending channels 624 and 625 whichextend from the first near end 618 to the drive assembly 634 located atthe second distal end 619, shown on FIG. 52. Channels 624, 625 supportshuttle-S3 626 for movement along third stick 18 from first near end 618to or toward second distal end 619. Shuttle-S3 626 has jaws 627 and 628,to clamp a brick. Top plate 623 supports bracket 629. Bracket 629supports idler pulleys 630, 631, 632, 633. Referring to FIG. 52, topplate 623 supports drive assembly 634 at the second distal end 619,which moves belts 635 and 636. Drive assembly 634 can move shuttle-S3626 and open and close jaws 627, 628. Thus shuttle-S3 can grasp a bricklocated at the first end 618 of third stick 18 and move said brick to ortoward the second end 619 of second stick 18 and unclamp the brick, inthe same manner as that of the first boom 12 and its shuttle. The thirdstick 18 has a void in the bottom plate 620 at the near end 618, whichis opposite the track formed by channels 624 and 625. This allows theshuttle-S2 606 of the second stick 17 to line up above the shuttle-S3626 to enable the clamps thereof to transfer a brick from shuttle-S2 606to shuttle-S3 626.

Fourth Stick

Refer to FIGS. 53, 54, 55. Referring to FIG. 53, fourth stick 19 has afirst near end 637 and a second distal end 638. Fourth stick 19 ispreferably constructed from carbon fibre sandwich panels for low weight.Alternatively, fourth stick 19 may be constructed from welded metalplates. Fourth stick 19 is of a substantially rectangular or box crosssection. Fourth stick 19 is constructed by welding or bonding bottomplate 640 to side plates 641, 642. Side plates 641, 642 are welded orbonded to top plate 643. Bottom plate 640 supports a track formed bylongitudinally extending channels 644, 645. Channels 644, 645 extendfrom the near end 637 to drive assembly 654 located at the distal end,and support shuttle-S4 646 (shown on FIG. 54) for linear movementtherealong. Referring to FIG. 54, shuttle-S4 646 has jaws 647 and 648 tograsp a brick. Bottom plate 640 supports bracket 649 at the near end 637which 649 supports idler pulleys 650, 651, 652, 653. Referring to FIG.55, bottom plate 640 supports drive assembly 654 at the distal end 638,inside fourth the stick 19. Drive assembly 654 moves belts 655 and 656in order to move shuttle-S4 646 along fourth stick and open and closejaws 647, 648, in the same manner as that of the first boom 12 and itsshuttle. Thus shuttle-S4 646 can grasp a brick located at the first end637 of fourth stick 19 and move it to or toward the second end 638 offourth stick 19 and unclamp the brick. Referring to FIG. 54, the fourthstick 19 has a void in the top plate 643 at the near end 637, which isopposite the track formed by channels 644 and 645. This allows theshuttle-S3 626 of the third stick 18 to line up above the shuttle-S4 646to enable the clamps thereof to transfer a brick from shuttle-S3 626 toshuttle-S4 646.

Fifth Stick

Refer to FIGS. 56, 57, 58 and 59. Referring to FIG. 56, fifth stick 20has a first near end 657 and a second distal end 658. Fifth stick 20 ispreferably constructed from carbon fibre sandwich panels for low weight.Alternatively, fifth stick 20 may be constructed from welded metalplates. Fifth stick 20 is of a substantially rectangular or box crosssection. Fifth stick 20 is constructed by welding or bonding bottomplate 660 to side plates 661, 662. Side plates 661, 662 are welded orbonded to top plate 663. Top plate 663 supports a track formed bylongitudinally extending channels 664, 665, which extend from the nearend 657 to the drive assembly 663, along the inside of the fifth stick20. Referring to FIG. 57, channels 664, 665 support shuttle-S5 666 forlinear movement therealong. Shuttle-S5 666 has jaws 667, 668 provided togrip a brick. Top plate 663 supports bracket 669 at the near end 657which supports idler pulleys 670, 671, 672, 673. Referring to FIG. 58,top plate 663 supports drive assembly 674 at the distal end 658. Driveassembly 674 moves belts 675 and 676 in order to move shuttle-S5 666 andopen and close jaws 667, 668 (shown in FIG. 57). Drive assembly 674moves belts 675 and 676 in order to move shuttle-S5 666 along fifthstick and open and close jaws 647, 648, in the same manner as that ofthe first boom 12 and its shuttle. Shuttle-S5 666 can grasp a brickpresented by shuttle-S4 646 located through a void located at the nearend 657 of the bottom plate 660. Shuttle-S5 666 then moves the brickalong the inside of fifth stick 20 to the second distal end 658 of fifthstick 20, where it will be unclamped.

The panels or plates making up each of the first stick 15, second stick17, third stick 18, fourth stick 19 and fifth stick 20 may be providedwith removable panel portions (not shown) to provide access forservicing of internal componentry within each stick.

Boom Cable Chains

Cable chains are used to route power and signals to and from the servomotors. The arrangement of the cable chains provides a compact over allcross section of the folding boom.

Referring to FIG. 65, bottom plate 218 of first boom 12, supports afirst end 735 of cable chain 112. Cable chain 112 is also visible inFIGS. 11, 18, 19. The top plate 22 of second boom 14, supports a secondend 736 of cable chain 112.

First near end 637 of fourth stick 19 supports a first end 737 of cableduct 733. Second end 738 of cable duct 733 supports a first end 739 ofcable chain 734. The bottom plate 660 of fifth stick 20, supports thesecond end 740 of cable chain 734. Cable chain 734 and cable duct 733are also visible in FIG. 56.

Referring to FIG. 66, the bottom plate 524 of second boom 14, supports afirst end 741 of cable chain 563. The top plate 623 of third stick 18supports a second end 742 of cable chain 563. Cable chain 563 is alsovisible in FIGS. 39, 40, 41, 42.

Referring to FIG. 67, the bottom plate 524 of second boom 14 supports afirst end 743 of cable chain 564. The top plate 643 of fourth stick 19supports a second end 744′ of cable chain 564. Cable chain 564 is alsovisible in FIGS. 39, 40, 41, 42.

Referring to FIGS. 1 and 5, cables (not shown) are routed from theelectrical cabinet 82 through the frame 3, through the centre of slewring 11, up through the inside of tower 10 and into first boom 12, theninto cable chain 112 (shown in FIG. 65), then into second boom 14.Referring to FIG. 65, cables (not shown) are routed from second boom 14,to first stick 15, and to cable chain 565 and then into second stick 17,and as shown in FIG. 66 also into cable chain 563 and then into thirdstick 18, and as shown in FIG. 67 also into cable chain 564 and theninto fourth stick 19.

Referring to FIG. 65, (cables not shown) are routed from fourth stick19, through cable duct 733 into cable chain 734 then into fifth stick20. From fifth stick 20, cables not shown are routed to the brick layingand adhesive applying head 32.

Flipper

Refer to FIGS. 59, 60, 61. Referring to FIG. 59, a pivotable clamp inthe form of a flipper assembly 687 has jaws 690 and 693 to grip a brickand can then translate and rotate the brick to move it past an adhesiveapplication nozzle 121, 122, 123, 124 and 125 and then present the brickfor transfer to the laying arm. The flipper assembly 687 is located atthe distal end 658 of the fifth stick 20.

FIG. 80A to 80Q show a sequence for a brick as it passes from the fifthstick to its laid position.

During the laying of bricks, the brick laying and adhesive applying head32 is held at a constant tilt relative to the ground. The pose of thefoldable boom is varied to position the brick laying and adhesiveapplying head 32 appropriately for the brick laying and adhesiveapplying head 32 to lay bricks in the required position. The angle ofthe stick assembly, varies according to the required pose of thefoldable boom. The flipper assembly 687 is used to receive a brick fromthe stick assembly (FIG. 80A) and move the brick to a position suitablefor an adhesive applicator 777 in the brick laying and adhesive applyinghead 32 to apply glue to said brick (FIGS. 80D-80G), and then for thebrick laying gripper 44 to lay the brick (FIG. 80Q). Referring to FIG.60, the flipper assembly 687 rotates about axis 33. The flipper assembly687 has a gripper with jaws 690 and 693 that can slide toward or awayfrom the axis of rotation 33 (which is the same horizontal axis of themount of the brick laying and adhesive applying head 32 to the end offifth stick 20). The gripper can extend into the fifth stick 20 to graspa brick (FIG. 80B). The gripper then retracts to a position near theaxis of rotation 33 (FIG. 80C) so that the brick is clear of the fifthstick 20. The brick is then rotated for the application of adhesive(FIG. 80D). The adhesive application nozzles are extended out over thebrick (FIGS. 80E, 80F). The adhesive nozzles direct adhesive downwardsso that gravity assists in applying the adhesive to the brick. Theadhesive application nozzles are retracted whilst directing adhesiveonto the brick (FIG. 80G). The flipper 687 then rotates (FIG. 80H) toorient the brick vertically (FIG. 80J), so that adhesive applicationnozzles can apply adhesive to the end of the brick. The flipper thenrotates (FIG. 80K) to invert the brick (FIG. 80L) so that the adhesiveis on the bottom of the brick. The flipper 687 then extends the gripperout (FIG. 80M), to present the brick in a position where the bricklaying gripper 44 can then grasp the brick (FIG. 80N). The flippergripper then releases the brick and the flipper gripper then translatesin a reverse direction whilst the flipper rotates in a reverse rotation(FIG. 80P, 80Q) so that the gripper is returned to its starting position(FIG. 80A).

A detailed description of the flipper assembly follows.

Refer to FIG. 59. Fifth stick 20 supports the flipper assembly 687 aboutthe same horizontal axis 33 as the brick laying and adhesive applyinghead 32 is attached to the distal end of the fifth stick 20 (see FIG.80A).

Refer to FIGS. 58, 59, 60 and 61. Referring to FIG. 59 the fifth stick20 supports a bearing reducer 677 and a servo motor 678. Bearing reducer677 supports an arm 679 of the flipper assembly 687 on its output, and aservo motor 678 rotates the input of bearing reducer 677. This rotatesarm 679 and hence the flipper assembly 687 about axis 33. Referring toFIG. 60, the arm 679 supports a linear guide 680 which slideablysupports a bearing car 681 for movement between a first end 707 and asecond end 708 of the arm 679. A base plate 682 mounts to the bearingcar 681, perpendicularly to the travel extent thereof. Referring to FIG.61, a servo motor 684 for movement of the base plate 682 is mounted viaa spacer 683 to the arm 679. Referring to FIG. 60, a servo motor 686 formovement of jaws 690 and 693 is mounted on motor mount plate 685 whichis supported on base plate 682. Base plate 682 supports linear guides688, 689 which slideably support bearing cars 691 and 692 respectively.Bearing car 691 supports jaw 690, and bearing car 692 supports jaw 693.Servo motor 686 drives pulley 694 which drives pulley 696 connected toleadscrew 695 via endless toothed belt 697. Referring to FIG. 61, baseplate 682 supports a bearing 700 which rotateably supports the leadscrew695. Referring to FIG. 60, jaw 690 supports a nut 698, and jaw 693supports a nut 699, which nuts 698 and 699 are engaged with theleadscrew 695. Thus servo motor 685 drives the jaws 690 and 693 to clampand unclamp a brick.

Referring to FIG. 60, the arm 679 supports a bracket 701 with an idlerpulley 702 near end 708. Servo motor 684 (shown in FIG. 61) drives apulley 703, which drives pulley 702 via endless belt 704. The base plate682 has a clamp plate 705 (shown in FIG. 61) which clamps belt 704. Thusthe servo motor 684 linearly moves base plate 682 along linear guide680.

Refer to FIG. 59. Servo motor 678 can rotate arm 679 so that linearguide 680 is aligned parallel with the channels 664, 665 in fifth stick20.

Jaws 690 and 693 can be moved by servo motor 684 towards the seconddistal end 658 of fifth stick 20 to pick up a brick (see FIG. 80B) thatis being held by jaws 667, 668 of shuttle-S5 666. Servo motor 686 canthen close jaws 690 and 693 to grasp the brick. Servo motor 684 can thenmove jaws 690, 693, holding the brick towards first end 707 of arm 679(see FIG. 80C). Servo motor 678 can then rotate arm 679 so that the topsurface of said brick is presented flat, ready for adhesive applicationby the adhesive application system 150 (see FIGS. 80 D to G).

Optionally, servo motor 684 can then rotate arm 679 through 90 degreesso that the end of said brick is presented flat, ready for adhesiveapplication by the adhesive application system 150 (see FIGS. 80H andJ). It should be noted that in some structures, such as for walls thatwill be rendered, it is not necessary to apply adhesive to the vertical(or “perp”) joints of the bricks. Optionally, servo motor 684 can thenrotate arm 679 through 180 degrees so that the opposite end of saidbrick is presented flat, ready for adhesive application by the adhesiveapplication system 150, thereby applying adhesive to the bottom and bothends of said brick.

Servo motor 684 can then rotate arm 679 through 180 degrees (or 90 or270 degrees, depending on which faces of the brick had adhesive appliedto them), so that said brick is inverted, ready to be picked up by thelaying arm gripper 44 (see FIGS. 80K to Q). In this way the glue isapplied to the bottom of said brick that will be laid by the laying arm40.

FIG. 75 shows a side view of the brick laying and adhesive applying head32 and fifth stick 20. FIG. 75 shows the sequence of the brick 797 froma first position 791, to a second position 792, to a third position 793to a fourth position 794 to a fifth position 795 to a sixth position796. In first position 791, brick 797 is gripped by shuttle-S5 666 (notshown in FIG. 75). The flipper jaws 690 and 693 are moved to grasp thebrick 797 and then shuttle-S5 666 releases the brick 797. The brick 797is then translated to second position 792, then rotated to thirdposition 793. Adhesive is then applied to the brick 797. Brick 797 isthen optionally rotated to vertical position 794. Brick 797 is thenrotated to a fifth position 795 and then translated to a sixth position796.

Adhesive

Referring to FIG. 5, the frame 3 supports an adhesive container 110 andan adhesive pump 111. The adhesive pump 111 supplies pressurisedadhesive to fluid conveying apparatus in the form of a hose which runsout along the boom and through the flexible energy chains 112 (shown inFIG. 65), 564 (shown in FIG. 67) and 740 (shown in FIG. 65) provided inthe telescopic boom and telescopic sticks, to the brick laying andadhesive applying head 32. Adhesives can be one pack or two pack, andshould have some flexibility when set in order to avoid fracturing dueto uneven expansion and contraction in the built structure. Suitableadhesives are single pack moisture curing polyurethane such as Sika“Techgrip”, Hunstman “Suprasec 7373” or Fortis AD5105S, single packfoaming polyurethane such as Soudal “Souda Bond Foam” or Weinerberger“Dryfix”, two part polyurethane such as that made by Huntsman, MSPolymer (Modified Silane Polymer) such as HB Fuller “Toolbox”, two partepoxy such as Latipoxy310 and methacrylate adhesive such as “Plexus”. Itwould be possible but less desirable (due to strength, flexibility and“pot life” and clean up reasons) to utilise water based adhesives suchas latex, acrylic or cement based adhesives similar to variouscommercially available tile glue or Austral Bricks ‘Thin Bed Mortar”.

Refer to FIGS. 12 and 13. The adhesive applicator 777 has an adhesivehead fitted with nozzles 121, 122, 123, 124 and 125, shown schematicallyin FIG. 13. The adhesive flow is controlled by electrically operablevalves 118 and 119, located in a manifold head 117, close to the nozzles121, 122, 123, 124 and 125, which are also supported on the manifoldhead 117. Space within the laying head is very restricted. The nozzlesprovided in two groups comprising a central group of nozzles 121, 122and 123 supplied by valve 118, and a peripheral group of two outernozzles 124 and 125 supplied by valve 119. The manifold head 117 issupported on a mechanism that can project the nozzles out to reach thelength of a brick, and retract the nozzles to provide clearance so thatthe brick can be rotated and also by retracting the nozzles clearance isprovided so that the laying head can be folded against a retracted stickassembly for compact transport. To achieve the extension and retraction,the nozzles are supported on a chain that can only bend one way and thechain is extended or retracted by a sprocket driven by a servo motor. Adetailed description follows.

Refer to FIGS. 12, 13, 62 and 71. Referring to FIG. 62, the brick layingand adhesive applying head 32 supports an adhesive applicator assembly777. Referring to FIG. 71, the adhesive applicator assembly 777 has acurved guide 113 attached to the brick laying and adhesive applying head32. The curved guide 113 supports a tongue member in the form of asliding chain 114 that can only bend one way. The sliding chain 114 ismoved by a servo powered sprocket 115. The brick laying and adhesiveapplying head 32 supports a straight guide 784 into which the slidingchain 114 may be retracted. The distal end 116 of the sliding chain 114supports a manifold 117 that supports two valves 118, 119. Each valve118, 119 is connected to the pressurised adhesive supply 120 provided bythe adhesive pump 111 mounted to the frame 3 (shown in FIG. 5). Thefirst valve 118 is connected to three central glue nozzles 121, 122,123, and the second valve 119 is connected to two outer glue nozzles124, 125 (shown schematically in FIG. 13). The inner nozzles 121, 122,123 are provided to allow glue to be applied to the top face of a narrowor internal brick, while the outer nozzles 124, 125 allow glue to beapplied to the outer edges of the top face of a wide or external brick126. The valves 118, 119 may be operated individually or together tosupply glue to the inner nozzles 121, 122, 123, the outer nozzles 124,125 or all nozzles 121, 122, 123, 124 and 125. The adhesive is appliedin a direction extending downwardly from the valves on the manifold, themanifold being disposed on the sliding chain 114 which is disposedhorizontally.

Refer to FIGS. 72 and 73. Referring to FIG. 72, the sliding chain 114has a plurality of body portions in the form of hollow links 778 and aplurality of chain links in the form of joiner links 779. Joiner links779 are standard items used to join power transmission chain, such as BSroller chain 16-B1 or ANSI roller chain 80-1. Referring to FIG. 73,hollow link 778 is provided with lugs 780, 781 to engage the pins 782 ofjoiner links 779 shown in FIG. 72. Hollow link 778 is provided with alongitudinally extending hole 783 for the passage of cables (not shown)and the pressurised adhesive 120 (see FIG. 13). The hollow links haveends that contact each other to prevent over extension of the slidingchain, allowing the sliding chain to be extended outward from the tip ofthe curved guide and retain a straight configuration, being bendableupward only, about the axes provided by the connection of the hollowlinks with the joiner links.

Referring to FIG. 74, the straight guide 784 is fitted with a lid 788.In FIG. 71 curved guide 113 is shown with the lid 787 removed forclarity. Straight guide 784 is shown without the lid 788 for clarity.

Referring to FIG. 72, consider the example of first hollow link 778,joiner link 779 and second hollow link 784′. It can be seen that secondhollow link 784′ can pivot upwards relative to first hollow link 778,but second hollow link 784′ cannot pivot downwards relative to firsthollow link 778. By extension of the logic to the plurality of hollowlinks 778 and joiner links 779, the sliding chain 114 can only curveupwards and not curve downwards.

Preferably the hollow links 778 are manufactured from a material with alow coefficient of friction such as acetal copolymer or UHMWPE (UltraHigh Molecular Weight Polyethylene) plastic. The curved guide 113 andstraight guide 784 may be manufactured from a material with a lowcoefficient of friction such as acetal plastic.

FIG. 74 shows a top view of straight guide 784. The straight guide 784is provided with grooves 785, 786 so that joiner links 779 do not touchstraight guide 784. Straight guide 784 may then be constructed from amaterial such as aluminium alloy which is more robust than acetalplastic.

Referring to FIG. 71, the curved guide 113 is also provided with grooves789, 790 so that joiner links 779 do not touch curved guide 113. Curvedguide 113 may then also be constructed from a material such as aluminiumalloy which is more robust than acetal plastic.

The tongue in sheath arrangement of the adhesive applicator allows asingle axis of servo motion control to move a nozzle for application ofadhesive whilst maintaining a vertical nozzle orientation and also toretract the nozzle to allow for movement of the brick to the next stepof the process. The laying head space is quite limited, so to achievethe application and retraction with more conventional linear movementmechanisms or articulating arm robots would require the use of two ormore servo axes of motion or the addition of linkages and cammechanisms.

Brick Laying and Adhesive Applying Head

Refer to FIG. 62. The brick laying and adhesive applying head 32supports a brick laying head in the form of a spherical geometry robot36 and the adhesive applicator assembly 777 along with a vision systemand tracking system. After application of adhesive as described above,the brick laying and adhesive applying head 32 takes a brick from thejaws 690 and 693 of the flipper assembly 687 and moves it to a positionwhere it is laid. The laying head also compensates for movement anddeflection of the boom, so that the brick is laid in the correctposition.

Refer to FIGS. 1, 12 and 62. Referring to FIG. 62, the articulated bricklaying and adhesive applying head 32 has a body 801 with arms 803 and805 forming a clevis which extends obliquely downward from the body 801.The arms 803 and 805 have apertures 807 and 809 to receive pins topivotally mount the head 32 and the flipper assembly 687 about secondhorizontal axis 33 at the distal end 658 of the fifth telescopic stick20 (see FIG. 1). Referring to FIG. 1, the brick laying and adhesiveapplying head 32 articulates about horizontal axis 33 substantiallyparallel to the articulation axis 16 of the first stick 15 and thearticulation axis 13 of the first boom 12. The pose of the brick layingand adhesive applying head 32 is controlled by movement of a ram 35.

Referring to FIG. 62, the articulated brick laying and adhesive applyinghead 32 supports a brick laying head comprising a spherical geometryrobot 36. The spherical geometry robot 36 has a linearly extendable arm40 with a brick laying clamp in the form of a gripper 44 fitted at thelower end thereof. Referring to FIG. 1, the spherical geometry robot 36has the following arrangement of joints: arm mount-roll angle 37, armmount-pitch angle 38, arm sliding (arm length or linear extension) 39,wrist pitch angle 41, wrist roll angle 42, gripper yaw angle 43 and withgripper 44 fitted to rotate about yaw axis 45. This configurationprovides pole free motion within the working envelope.

Referring to FIGS. 62 and 83, to achieve the arm mount-roll angle 37adjustment, the body 801 supports a servo motor 810 with a belt drivinga bearing reducer 812 connected to the base 811 of a clevis 813, thebase being rotatable relative to the body 801 about a horizontal axiswhich runs normal to the clevis 813 axis. To achieve the arm mount-pitchangle 38 adjustment, the clevis 813 supports about its axis 814 a servomotor 816 attached to the body 801 driving via a belt a bearing reducer818 connected to a base 815 for the arm 40.

The arm 40 has linear guides 820 which co-operate with bearing cars 822(see FIG. 84) on the base 815 to guide linear extension of the armrelative to the mount, to allow the arm 40 to move in a direction(typically straight up and down, but this depends on the pose) normal tothe axis 814 of the clevis 813 to provide sliding movement of the arm40. This linear extension of the arm is controlled by a servo motor 823attached to the base 815 with reduction drive pulleys connected by atoothed belt 825 driving a pinion 827 engaging a rack 829 locatedextending along the arm 40.

The brick laying clamp/gripper 44 mounts for controlled rotation by aservo motor 830 driving a bearing reducer 831 about an axis normal andperpendicular to the plane of its jaws 833, 835 and bearing reducer on aclevis 817 to provide the gripper yaw angle 43 adjustment; a universaljoint formed by mechanism 819 comprising servo motor 837 and bearingreducer 839 connected by toothed belt 841 and pulleys provides wristpitch angle 41 adjustment; and mechanism 821 comprising servo motor 843and bearing reducer 845 driven by toothed belt 847 and pulleys provideswrist roll angle 42 adjustment (shown in FIG. 1). Details of these servomotors and drives can be seen in FIG. 85.

The brick laying and adhesive applying head 32 supports a hook 151 thatcan be used to lift items such as windows, doors, lintels and otheritems not shown.

Refer to FIG. 12 and FIG. 13. The brick laying and adhesive applyinghead 32 supports machine vision cameras 127, 128 mounted to view bothsides of the brick 126 shown schematically in FIG. 13.

The jaws 835, 833 of the laying head gripper 44 are independentlymovable by independent lead screws 849, 851, engaged with nuts 853, 855connected with the jaws 835, 833, and moveable by servo motors 857, 859,via drive belts 861, 863 respectively. This allows the offset grippingof a brick. The arrangements for moving the jaws 835, 833 use leadscrews 849, 851 and co-operating nuts 853, 855, driven by separate servomotors 857, 859, respectively, similar to that as described for othergrippers utilised elsewhere in the embodiment, apart from the drives forthe jaws being separate in order to allow independent movement of thejaws.

As can be seen in FIG. 62, when considered with FIG. 71, the straightguide 784 of the adhesive applicator assembly 777, into which thesliding chain 114 may be retracted, is mounted in the body 801 of thebrick laying and adhesive applying head 32, behind the servo motor withbearing reducer that connects to clevis 813. The curved guide 113 of theadhesive applicator assembly 777 descends/depends downwardly obliquely,substantially following the extent of the arms 803 and 805 for a shortdistance, before curving toward horizontal so that the sliding chain ispresented extending substantially level, subject to the alignment of thebrick laying and adhesive applying head 32 as controlled by the ram 35,and presented above where the flipper assembly 687 holds the brick. Withthis arrangement, the adhesive applicator assembly 777 is kept clear ofpositions through which arm 40 and gripper 44 of the spherical geometryrobot 36 could be required to move.

Tracker and Slab Scan

Referring to FIGS. 1, 12, 62, the top of the brick laying and adhesiveapplying head 32 supports a tracker component 130. The tracker component130 may be a Leica T-Mac or an API STS (Smart Track Sensor). Alternatelytracker component 130 may be a single SMR (Spherical Mount Reflector) orcorner cube reflector, or two or three SMRs or corner cube reflectors ora Nikon iGPS or any other suitable tracking device. Preferably thetracker component 130 provides real time 6 degrees of freedom positionand orientation data at a rate of preferably greater than 10 kHz, orpreferably 1000 Hz to 10 kHz, or preferably at a rate of 500 Hz to 1000Hz or preferably a rate of 300 Hz to 500 Hz or 100 Hz to 300 Hz or 50 Hzto 100 Hz or 10 Hz to 50 Hz. The laying arm 40 and or the gripper 44 ofthe laying arm 40 may support a second or third tracker component 131,132 of the same or different type to the first tracker component 130.

Referring to FIG. 3, a tracker component 133 or components, 133, 134,135 are set up on the ground adjacent to the concrete slab 136 or on anearby structure. The tracker component 130 on the laying headreferences its position relative to the tracker component 133 orcomponents 133, 134, 135 set up on the ground or structure.

Referring to FIG. 12, the brick laying and adhesive applying head 32supports a camera 137 that views the ground, slab 136 or structure orobjects below it. The brick laying and adhesive applying head 32 isprovided with laser or light projectors 138 that project dots or lines139 onto the ground, footings, slab 136 or objects below it. Machinevision is used to determine the 3D shape of the ground, footings, slab136 or objects below the laying head. Alternatively, the brick layingand adhesive applying head 32 is fitted with a laser scanner 140. Afterpositioning the truck and unfolding the boom, the brick laying andadhesive applying head 32 is moved around by moving the boom and stickassembly 141 so that the brick laying and adhesive applying head 32 isoptionally moved around the edge of the slab 136 and optionally aboveall positions that will be built upon. The machine vision system 143 orscanner 140 scans the slab 136 and the areas to be built on to firstlyalign the slab 136, machine 2 and working coordinate systems to theircorrect locations and secondly to quality check the slab 136 and checkits flatness and level. If the slab 136 is not flat or level withintolerance the first course of bricks or selected bricks not shown can beindividually machined by the router module 47 (prior to beingtransported to the tower 10 and boom and stick assembly 141) to correctthe out of level, flatness or height. Optionally a brick may have agroove or notch or pocket machined in it to avoid a bump or defect orobject (such as a pipe projecting through the slab) on the slab 136.

As the brick laying and adhesive applying head 32 lays a brick 144, themachine vision 143 or laser scanner 140 is used to measure the laidbrick 144 so that the height of the laid brick 144 is stored and laterused to adjust the laying height of the dependant bricks that are laidon top of it on the next course. If the height is over tolerance, thedependant bricks above it can be machined to a reduced thickness by therouter 47.

The concrete slab 136 may alternatively be a slab of earth, rock, wood,plastic or other material or a steel deck or footings. The slab 136 maybe on the ground or suspended.

FIG. 14 shows a side view of a slab 136 with a first course 163 of aplurality of bricks 159, 160, 161, 162, 163. The slab 136 may not beflat and in the example of FIG. 14 has a hump 164. To obtain a flat top165 of the first course 163, the bricks, 159, are machined by the routermodule 47 or cut to height with the saw 46, prior to being transportedto the tower 10 and boom and stick assembly 141.

The bricks are normally fired clay but may be concrete, aeratedconcrete, plastic, foam, wood, compressed wood, recycled material or anyblock or brick shaped component or any interlocking component or arandom shaped component such as rock or stone or a sculpted or mouldedcomplex object. For applications where the supplied dimensions or shapeof the bricks, blocks or objects to be laid vary significantly from thedesign dimensions, additional routers or saws may be added to themachine so that routing or sawing of the bricks, blocks or objects canoccur simultaneously on a number of bricks, blocks or objects inparallel.

Block Moulding

In a further variation of the machine not shown but described here, themachine is provided with an on board brick or block moulding machine. Afiller mixture of for example sand, clay, aggregate stone or wood chipor wood fibre is supplied to a hopper. The hopper may then optionallysupply the filler mixture to a mixer which may add a binder materialsuch as cement or polymer adhesive or water or a thermoplastic powder orfiber. The mixer then supplies the mixed filler and binder to a brickmoulding press. Optionally the moulded bricks may pass through a curingstation which may apply a chemical curing agent or heat or radiation.The curing station may apply steam to rapidly cure a concrete binder.Alternatively, the curing station may apply UV light to cure a UVsensitive binder resin. Alternatively, the curing station may applymoisture to cure a moisture curing polyurethane binder material.Alternatively, the curing station may apply heat to cure an epoxybinder. The moulded bricks may then be used by the automated bricklaying machine. Alternatively, the filler mixture may contain athermoplastic material such as recycled plastic. When pressed under heatthe plastic binder melts, fusing the sand or aggregate or wood fibermaterial when it cools. Brick or block making presses are commerciallyavailable from suppliers such as Besser.

Harsh Environment

In an adaptation of the machine, with radiation protection, the machinecould be used for erecting containment structures in nuclear disasterzones.

In a further adaptation of the machine, the machine may be adapted towork in a low pressure atmosphere or in a vacuum and in the presence ofionising radiation. In this format with an integral automated brick orblock making unit, the machine could be used for building structures onthe moon or Mars or in other extra-terrestrial locations.

Advantages of the Invention

The invention provides an improved automated brick laying machine thatis compact and mobile and able to drive on public roads. The arrangementand configuration of components allows the machine to have a very largeworking envelope whilst also being compact for road travel. It iscapable of receiving packs of bricks and processes them to in effect 3Dprint a full size structure of walls. The machine is electronicallyprogrammed and can build a wide variety of structures.

The invention uses thin bed mortars or liquid adhesives which need notsupport the weight of a brick so can be very fluid and may contain noparticulates or may contain very fine non-abrasive particulates, ratherthan abrasive sand which is used in thick bed mortars used intraditional manual brick-laying. Given variations in slab height, thedesire to completely remove the need for a thick bed of mortar or thickadhesive between the slab and the first course of bricks requires a verylevel slab, level within a few mm of height tolerance. To achieve theslab height tolerance required for use of thin be mortars would incursignificant additional cost from concrete contractors. The provision ofa router module in the invention allows bricks to be pre-machined basedon measured slab elevation at the required brick location, which resultsin only a slight increase in build time, to machine in the router, eachbrick in the first course, so that the top of the first course is laidat the correct height and level, even on inaccurate slabs. Deviations ofbetween 0 and 50 mm of flatness and level can be easily accommodated.Larger deviations could be accommodated if required.

To build common house size structures, the boom needs to reach out 30 m.To manoeuvre on suburban roads a short truck is advantageous. To fit onsmall building sites a compact machine is advantageous. Bricks beingconveyed along a boom, must be restrained, so that they can't fall anddamage structures or injure personnel. By conveying the bricks along theinside of the boom, the cross section of the boom can be made smallerthan the total cross section of a boom with external guarding to containexternally conveyed bricks. The smaller boom cross section enables asmaller and more compact machine to be built. The present invention hascable chains routed inside the boom. By conveying the bricks internally,and routing the services internally, the structural cross section of theboom is maximised for a given over all cross section, thereby increasingthe stiffness of the boom which reduces the dynamic displacement of theboom. A light weight boom is also possible due to the large crosssection.

The present invention utilises a series of shuttles that transfer abrick from one shuttle to the next. This system has the advantage thatthe movement of bricks along the boom is completely independent of thebrick preparation or laying processes. In this way, the laying rate canbe kept as high as possible. Both the brick preparation, the bricktransport and the laying process can proceed at the individual maximumrates, limited only by the availability of the bricks into each process,and the availability of a consumer process for the output of the bricks.

The invention is intended to build all of the external and internalwalls of a structure. Whilst it would be possible for the invention tobuild only some of the brick walls in a structure, with the remainingwalls being manually constructed later with manually laid bricks ormanually placed stud walls or precast panels, it should be understoodthat the invention allows the rapid and accurate placement of bricks andconstruction of brick walls faster and at a cost equal to or lower thanthe cost of manually built walls using bricks or stud framing or precast concrete.

It should be appreciated that the scope of the invention is not limitedto the particular embodiment described herein, and the skilled addresseewill understand that changes can be made without departing from thespirit and scope of the invention.

The invention claimed is:
 1. A brick laying machine incorporated in avehicle, said machine having a foldable boom, foldable about at leastone folding axis, said foldable boom being locatable in a folded stowedposition longitudinally along said vehicle, and moveable to unfoldedextended positions away from said vehicle; said boom having a near endarranged for pivotal movement about a first horizontal axis located on aturret, said turret being rotatable about a vertical axis; said foldableboom having first conveying apparatus to convey bricks therealong, to abrick laying and adhesive applying head located at a remote end of thefoldable boom; and having fluid conveying apparatus to convey adhesivetherealong, to an adhesive applicator located in said brick laying andadhesive applying head; said machine having a carousel extending atleast partially around said turret near the base thereof, said turrethaving second conveying apparatus to convey bricks vertically from saidcarousel to said first conveying apparatus, said carousel beingrotatable about a vertical axis to present a brick for access by saidsecond conveying apparatus; said machine having at least one brickmachining tool located beside said stowed position and having a loadingbay to receive packs of bricks; said machine having programmable brickhandling apparatus to convey bricks one by one from said loading bay tosaid carousel, optionally via said at least one brick machining tool, aspre-programmed.
 2. A brick laying machine as claimed in claim 1 whereinsaid first conveying apparatus comprises at least one shuttle equippedwith a clamp to releasably hold a brick, said shuttle running along atrack extending along at least part of said boom.
 3. A brick layingmachine as claimed in claim 1 wherein said foldable boom comprises afirst boom element and a second boom element pivotable about the atleast one folding axis that is spaced from said first horizontal axis,and parallel therewith.
 4. A brick laying machine as claimed in claim 3wherein each boom element has a shuttle equipped with a clamp toreleasably hold a brick, said shuttle running along a track extendingalong each said boom element.
 5. A brick laying machine as claimed inclaim 3 wherein at least one of said first boom element and said secondboom element, has further elements arranged in telescopinginterconnection.
 6. A brick laying machine as claimed in claim 1 whereineach element has a said track and one said shuttle arranged to run alongsaid track, between opposed ends of each said element.
 7. A brick layingmachine as claimed in claim 6 wherein said tracks are locatably arrangedinternally inside said elements, and said shuttles run inside theirrespective elements.
 8. A brick laying machine as claimed in claim 1wherein the second conveying apparatus comprises a turret trackextending vertically along said turret, said turret track having ashuttle with a turret shuttle clamp to clamp a brick, the shuttleconveying the brick from the carousel to the shuttle in the near end ofthe foldable boom.
 9. A brick laying machine as claimed in claim 8wherein the turret supports a brick rotating mechanism having a clamp toclamp a brick presented by said turret shuttle clamp and wherein atleast one of: a. said brick rotating mechanism being provided to rotatea brick so that its longitudinal extent aligns with the longitudinalextent of said first boom element, for presentation to the shuttle inthe near end of the foldable boom; and b. said brick rotating mechanismis mounted about said first horizontal axis.
 10. A brick laying machineas claimed in claim 1 wherein the carousel has a carousel clamp to clampa brick received from the programmable brick handling apparatus.
 11. Abrick laying machine as claimed in claim 10 wherein the carousel clampcan pivot from a first position in which it receives a brick from theprogrammable brick handling apparatus to a second position in which itpresents the brick to a turret shuttle clamp.
 12. A brick laying machineas claimed in claim 1 wherein said turret, said carousel and said stowedposition are located along a central longitudinal axis of said vehicle.13. A brick laying machine as claimed in claim 1 wherein said at leastone brick machining tool comprises a first brick machining toolincluding a saw located to one side of the stowed position, and a secondbrick machining tool including a router located to another side of thestowed position.
 14. A brick laying machine as claimed in claim 13wherein said first brick machining tool includes a clamp at least oneof: a. located to clamp a brick on a side of a saw cutting bladeposition; and b. configured to clamp a brick on each side of a sawcutting blade position.
 15. A brick laying machine as claimed in claim13 wherein at least one of said first brick machining tool and saidsecond brick machining tool is contained in an enclosure with a coverproviding access for placement and removal of a brick by saidprogrammable brick handling apparatus.
 16. A brick laying machine asclaimed in claim 13 wherein the second brick machining tool at least oneof: a. includes a clamp to clamp a brick, and an orientation assembly toorient the clamped brick in space to present to the router, to routeslots and notches in bricks in order to chase cabling, or to mill bricksto a predetermined required height; b. is mounted on a tri-axis motionassembly for moving the router in any combination of movement in threedimensions; and c. includes a tool storage magazine spaced away from theclamp and orientation assembly and accessible by said router at apredetermined position of said tri-axis motion assembly, to access orstore a routing bit or milling bit.
 17. A brick laying machine asclaimed in claim 1 wherein said brick laying and adhesive applying headis pivotally mounted for controlled rotation to the remote end of thefoldable boom about a second horizontal axis located on a clevis, saidbrick laying and adhesive applying head including a pivotable clamp toreceive and clamp a brick presented by said first conveying apparatus,said pivotable clamp being pivotally mounted about said secondhorizontal axis; said brick laying and adhesive applying head supportingsaid adhesive applicator to apply adhesive to a brick presented by saidpivotable clamp; said brick laying and adhesive applying head having abrick laying head mounted thereto by a mount located in a position awayfrom said clevis, said brick laying head having a brick laying clampmoveable between a position to receive and clamp a brick held by saidpivotable clamp, to a position in which said brick is released and laid.18. A brick laying machine as claimed in claim 17 wherein the pivotableclamp is at least one of: a. mounted for rotation on the distal end ofsaid second boom element; and b. mounted on a linear sliding mount thathas travel extending in a direction linearly through said secondhorizontal axis and normal thereto.
 19. A brick laying machine asclaimed in claim 1 including a tracker component mounted to said bricklaying and adhesive applying head, wherein said brick laying andadhesive applying head has a robotic arm assembly with a brick layingclamp to grip and lay a brick, and said brick laying machine uses atracker system to measure the position of the tracker component andapplies compensating movement to the robotic arm assembly to correct forvariance between programmed tracker component position and measuredtracker component position.
 20. A brick laying machine as claimed inclaim 19 wherein a further tracker component is supported on said bricklaying clamp, and said brick laying machine uses a further trackersystem to measure the position of the further tracker component andapplies further compensating movement to the robotic arm assembly tocorrect for variance between programmed further tracker componentposition and measured further tracker component position.